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Range Rover : front suspension

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14 pages
Many steering and suspension items are secured using self locking nuts. Where self locking nuts have been removed, they MUST be replaced with new items of the correct type.
PANHARD ROD
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  . . . .   7891 SELF LOCKING NUTSMany steering and suspension items are securedusing self locking nuts. Where self locking nutshave been removed, they MUST be replaced withnew items of the correct type.DOR Remove and refitRemovingWorking underneath the vehicle remove thefixings at the mounting arm.2.Remove the fixings at the axle bracket.Withdraw the  rod.4.Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.Refitting5. Fit replacement bushes centrally in the rod.CAUTION: When pressing in the new bushesensure that pressure is applied to the outer edgeof the bush only and not to the rubber inner.6. Reverse 1 to 4. Tighten the fixings to the (see section  values).FRONT SUSPENSIONRADIUS ARMRemove and refitRemovingLoosen the road wheel retaining nuts.Raise the front of the vehicle using asuitablehydraulic floor jack. Support chassis onsuitable standsand remove the wheel,(remove both front wheels only if removingboth radius arms).Support the front axle weight using thehydraulic floor jack.Remove the fixings radius arm to chassis sidemember.5. Disconnect the track rod at the ball joint,using a suitable extractor.6. Remove the fixings, radius arm to axle.7. Lower the radius arm front end to clear theaxle and remove it from the vehicle.REVISED:  88Continued
   FRONT SUSPENSIONUsing a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.9. Fit the replacement bushes centrally in the.mraCAUTION: When pressing in the new bushesensure that pressure is applied to the outer edgeof the bush only and not to the rubber inner.10. Reverse 1 to 7. Tighten the fixings to thecorrect torque (see section  values).FRONT SHOCK ABSORBERRemove and refitRemovingI. Loosen the road wheel retaining nuts.2. Raise the front of the vehicle using a suitablehydraulic floor jack. Support the chassis onsuitable stands and remove the road wheel.(Remove both front wheels only if removingboth shock absorbers).3. Support the front axle weight using thehydraulic floor jack.2 7891 Remove the shock absorber lower fixing andwithdraw the cupwasher, rubber bush andseating washer. Remove the four shock absorber bracketfixings.6. Withdraw the shock absorber and bracketcomplete.7. Withdraw the lower seating washer, rubberbush and cupwasher.8. Removethe fixings,shock absorber tomounting bracket.9. Withdraw the mounting bracket.10. Lift off the top seating washer, rubber bushand cupwasher.Refitting11. Reverse instructions 1 to 10.REVISED: JULY
       Refitting5. Fit the shock absorber bracket retaining ring.Retain in position with a nut.6. Reverse 2 and 3.7. Remove the nut retaining the securing ring.8. Fit the front shock absorber.Refitting3.Position the fixing bolts in the slots in thechassis brackets.4.Fit the bump stop assembly.7891 FRONT ROAD SPRINGRemove and refitRemoving1. Remove the front shock absorber.CAUTION: During the following procedure avoidover stretching the brake hoses. If necessary,loosen the hose connector locknuts to allow thehoses to follow the axle.2. Lower the axle sufficient to free the roadspring.3. Withdraw the road spring.4. Withdraw the shock absorber bracket securing.gnirBUMP STOPRemove and refitRemoving1. Remove the fixings.2. Withdraw the bump stop assembly.FRONT SUSPENSION 603
FRONT SUSPENSIONANTI-ROLL BAR ASSEMBLY FRONTYEK1. Anti-roll bar2. Rubber bush3. Strap Nut, bolt, washerANTI-ROLL BAR FRONTRemove and refitRemove1. Mark for reassembly position of rubber busheson the anti-roll bar.2. Remove the tour nuts, bolts and washerssecuring the two bush straps.3. Remove the nuts, bolts, washers and rubberbushes from the ball joint links and removeanti-roll bar.4 5. Nut and washer6. Castellated nut and cotter pin7. Ball joint link arm RROANVGEERtifeR4. Position bushes on the anti-roll bar. Ensure thesplit points towards axle. Fit the anti-roll bar with the two straps. TOensure correct fit the angled sides of the barshould point down as shown. Loosely fit the  and  nuts.6  washers and rubber bushes. Using fit anti-roll bar to ball joint links. to the correct torque.7  to the correct torque the nuts  the straps.ADDITION: SEPT. 90.
 1991 ANTI-ROLL BAR BALL JOINT LINKS-FRONTRemove and refitRemove1. Remove the two nuts, bolts, washers andrubber bushes from the ball joint links. Remove cotter pin and loosen castellated nuta few turns.3. Release ball joint using special tool  1063Aas shown.4. Remove castellated nut and ball joint link.42II IItifeR5. Fit ball joint link and castellated nut.Ensurethe ball joint link arm points up. Tighten to thecorrect torque and fit new cotter pin.6. Align anti-roll bar to ball joint links.7. Fit bolts, washers and rubber bushes usingnew self locking nuts secure anti-roll bar toball joint links. Tighten to the correct torque.ADDITION: SEPT. SOFRONT SUSPENSION
   
SELF LOCKING NUTSMany steering and suspension items are securedusing self locking  self locking nutshave been removed, they MUST be replaced withnew items of the correct type.REAR ROAD SPRINGRemove and refitRemovingLoosen the rear road wheel retaining nuts.Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the chassis onstands and remove the wheels.Support the rear axle weight with the floor.kcajDisconnect the shock absorbers at one end.5. Position a suitable coil spring compressorcorrectly on the road spring.6. Compress the spring evenly to facilitateremoval.7. Lower the axle sufficient to free the roadspring from the upper seat.CAUTION: Avoid lowering the axle further thannecessary otherwise the rear brake flexible hosewil be damaged.8. Remove the spring retainer plate.9. Withdraw the road spring.10. Lift off the spring seat.Refitting11. Reverse 1 to  Ensure that the cotter pinsecuring the top shock absorber mounting islocated in the inboard hole.REAR SUSPENSION  REAR SHOCK ABSORBERRemove and refitRemovingLoosen the road wheel retaining nuts and raisethe rear of the vehicle using a suitablehydraulic floor jack.Support the chassis on stands. Remove theroad wheels and support the rear axle weightwith the floor jack.Remove the fixings and withdraw the shockabsorber the axle bracket. REVISED: MARCH 901
REAR SUSPENSION4. Remove upper fixings.NOTE:  shows 1990 Model Year topdamper fixing.5. Withdraw the shock absorber.6. If required, remove the mounting bracket atthe chassis side member.7. If required, lift out the mounting rubbers atthe upper end.Refitting8.Reverse items and 6 as applicable.9.Reverse items 1 to 5. Vehicles up to 1990Model Year when fitting the top shockabsorber fixings compress the mountingrubbers and locate the cotter pin in theINBOARD hole. The outer hole is NOTdesigned for this purpose.TINU Functional checkA Boge Hydromat levelling unit is located in thecentre of the  When the vehicle is unladen the levelling unit haslittle effect. The unit is self-energising and hencethe vehicle has to be driven before the unitbecomes effective, the time taken for this tohappen being dependent upon the vehicle load,the speed at which it is driven and the roughnessof the terrain being crossed.If the vehicle is overloaded the unit will fail to levelfully and more frequent bump stop contact will benoticed.Should the vehicle be left for a lengthy period, e.g.overnight, in a laden condition, it may settle. This isdue to normal internal fluid movement in the unitand is not detrimental to the unit performance.Before carrying out the checks below, verify thatthe vehicle is being operated within the specifiedmaximum loading capabilities. If the levelling unit isthen believed to be at fault, the procedure belowshould be followed.1. Check the levelling unit for excessive oilleakage and if present the unit must bechanged. Slight oil seepage is permissible.21987-90 2. Removeexcessivemud  fromunderneath the vehicle and any heavy itemsfrom inside the vehicle that are not part of theoriginal equipment.3. Measure the clearance between the rear axlebump pad and the bump stop rubber at thefront outer corner on both sides of thevehicle. The average clearance should be inexcess of 67mm (2.8 in). If it is less than thisfigure remove the rear springs and check theirfree length against the ‘Road Spring Data’.Replace any spring whose free length is morethan 20mm (0.787 in) shorter than the figuregiven. If after replacing a spring the averagebump clearance is still less than 67mm (2.8 in),replace the  unit..4.With the rear seat upright, load 450 kg (992lb) into the rear of the vehicle, distributing theload evenly over the floor area. Check thebump stop clearance, with the driving seatoccupied.5.Drive the vehicle for approximately 5 km miles) over undulating roads or graded tracks. Bring the vehicle to rest by light brake .application so as not to disturb the vehicleloading. With the driving seat occupied, checkthe bump stop clearance again.6.If the change in clearance is less than 20mm(0.787 in) the levelling unit-must be replaced.REVISED: MARCH 90
 1987-90TINU Remove and refitRemovingWARNING:Thelevellingunitcontainspressurized gas and must not be dismantled northe casing screwsremoved.Repair is byreplacement of complete unit only.1. Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the chassis onstands.2. Support the axle weight using the floor jack.3. Disconnect the suspension upper links at thepivot bracket.4.Ease up the lower boot.5.Unscrew the lower ball joint at the levellingunit push rod, using thin jawed wrenches.6.Remove the top bracket fixings at the crossmember.7.Withdraw the levelling unit and top bracketcomplete.Ease back the upper boot.9.Unscrew the upper ball joint at the levellingunit, using thin jawed wrenches.10.Withdraw the upper and lower boots and theirretaining spring rings.REAR SUSPENSIONRefitting11. Coat the ball pin threads with  gradeCVX or suitable equivalent sealant.12. Reverse items 1 to 10. Do not fully tighten thefixings until all items are in their fittedposition. Finally tighten to the correct. torque(see section  values). UNIT BALL JOINTSRemove and refitService tools:R01006 Extractor for axle bracket ball jointRemoving1. Remove the levelling unit.2. Remove the cotter pin and nut at the rear axlebracket.3. Extract the ball pin from the axle bracket usingExtractor 3
REAR SUSPENSION4. Withdraw the pivot bracket complete with balljoints.5. Unscrew the ball joint assembly for thelevelling unit.6. Remove the ball joint assembly from the axlebracket.7.Replacement ball joints are supplied ascomplete assemblies, less fixings, and arepre-packed with grease.8.The ball joint for the axle bracket must not bedismantled.9.The ball joints for the levelling unit may bedismantled and cleaned if required.10.Pack the ball joint with Dextagrease GP or anequivalent grease when assembling.11.Ensure that the ball seating is square in itshousing before refitting.Refitting12.Press the knurled ball joint into the pivotbracket.13.Screw the ball joints for the levelling unit intothe mounting brackets. If the ball joints do notscrew in easily and fully, remove and theassemblies ensuring that the plastic seats donot jam in the housings. Tighten to the correcttorque (see section  values).41987-90 RANGE Fit the pivot bracket complete with ball jointsto the rear axle. Tighten to the correct torque(see section 06-Torque values).15. Fit the levelling unit.BUMP STOPRemove and refitRemoving1. Rernove the fixings.2. Withdraw the bump stop assembly.RR 1607MRefitting3. Position the fixing bolts in the  in thechassis brackets.4.  the bump stop assembly,  the on the carrier to suit  chassisconfiguration.
        ROVER UPPER SUSPENSION LINKRemove and refit 1 to 6 and 9HSUBRemove and refit 7 and 8Removing1. Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the rear of thechassis on stands allowing the axle to be freelysuspended.2. Remove the fixings, upper link bracket toframe.Remove the fixings,upper links to pivotbracket.4.Withdraw the upper link complete with framebracket.Remove the fixing bolt.6.Separate link and bush assembly from bracket.REAR SUSPENSIONReplacing the bush7. Using a suitable hydraulic or bench press anda piece of metal tubing slightly smaller thanthe outside diameter of the bush, press outthe rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bushand not on the rubber inner.8. Fit the replacement bush assembly centrally inthe housing.CAUTION: When pressing in the new bushesensure that pressure is applied to the outer edge01 the bush only and not to the rubber inner.Refitting9. Reverse 1 to 6. Do not fully tighten the fixingsuntil all components are in position.10. Finally tighten all fixings to the correct torque(See Section 06 Torque Values).REVISED:  88
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