Range Rover Manual Suspension

8/3/2019 Range Rover Manual Suspension

1/14

PO;;; 1987FRONT SUSPENSION

SELF LOCKING NUTS,, _

. . Many 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.

PANHARD ROD

Remove and refit

Removing

1 .

2 .

3 .

4 .-. . .:.

:

Working underneath the vehicle remove the

fixings at the mounting arm.

Remove the fixings at the axle bracket.

Withdraw the Panhard rod.Using a suitable hydraulic or bench press and

a piece of metal tubing slightly smaller than

the outside diameter of the bush, press out

the rubber mounted bushes. Ensure the steeltubing locates on the outer edge of the bush

and not on the rubber inner.

i---

._ . . ..(

. .

Refitting

5. 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. Reve rse 1 to 4 . Tigh ten th e f ix in gs to the

correcttorque (see section 06-Torque values).

RADIUS ARM

Remove and refit

Removing

Loosen the road wheel retaining nuts.Raise the front of the vehicle using a suitable

hyd rau l i c f l oo r jack . Suppo r t chass is on

su it a b l e st a n d s a n d r em o v e t he w h e e l,

( r e m o v e b o t h f r o n t w h e e l s o n l y i f r e m o v i n g

both radius arms).

S u p p o r t t h e f r o n t a x l e w e i g h t using thehydraulic floor jack.

Remove the fixings - radius arm to chassis sidemember.

RR983M

5 . D i s c o n n e c t t h e t r a c k r o d a t t h e b a l l j o i n t ,

using a suitable extractor.

6. Remove the fixings, radius arm to axle.

7. Lower the radius arm front end to clear the

axle and remove it from the vehicle.

Continued

REVISED: jULY88 1


2/14


3/14

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RR;;;; 1987FRONT SUSPENSION 6 0

FRONT ROAD SPRING

Remove and refit

Removing

1. Remove the front shock absorber.

CAUTION: During the following procedure avoid

over stretching the brake hoses. I f necessary,

loosen the hose connector locknuts to allow the

hoses to follow the axle.

2 . Lower the ax le su f f i c ien t to f ree the road

spring.

3. Withdraw the road spring.

4. Withdraw the shock absorber bracket securing

ring. -57e

R R 1 5 9 3 M T ' M

BUMP STOP

Remove and refit

Removing

1. Remove the fixings.2. Withdraw the bump stop assembly.

Refitting

3 .

4 .

Pos i t ion the f ix ing bo l ts in the s lo ts in the

chassis brackets.

Fit the bump stop assembly.

Refitting

5. 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.

3


4/14

RANGEFRONT SUSPENSION lggl ROVER

ANTI-ROLL BAR ASSEMBLY FRONT

23 4

KEY

1. Anti-roll bar2. Rubber bush

3. Strap

4. Nut, bolt, washer

ANTI-ROLL BAR FRONT Refit

Rem ove and refit

Remove

1. Mark for reassembly position of rubber bushes

on the anti-roll bar.

2 . Remove the tou r nu ts , bo l ts and washe rs

securing the two bush straps.

3. Remove the nuts, bolts, washers and rubber

bushes from the ball joint links and remove

anti-roll bar.

4

5. Nut and washer

6. Castellated nut and cotter pin

7. Ball joint link arm

4. Position bushes on the anti-roll bar. Ensure the

split points towards axle.

5. F i t the an t i - ro l l ba r w i th the two s t raps . TOensure correct fit the angled sides of the bar

should point down as shown. Loosely fit the

bolts isashers and nyloc nuts.6 FII hrdt washers and rubber bushes. Us ing

ne\ \ I IUIS f i t an t i - ro l l ba r to ba l l j o in t l i nks .TIgh ivn to the correct torque.

7 rlghlt~n to the correct torque the nutsWC urlng the straps.

.

ADDITION: SEPT. 90


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;g ; 1991 FRO NT SUSPENSIO N

ANTI-ROLL BAR BALL JOINT LINKS-FRONT

Remove and refit

Remove

1 . Remove the two nu ts , bo l t s , washers andrubber bushes from the ball joint links.

2. Remo ve c otter pin and loosen ca stellated nuta few turns.

3. Relea se ball joint using spe c ial tool 1 8 C 1 0 6 3 Aas shown.

4. Remo ve c astellated nut and b all joint link.

4 1 2 II II

RR2926M

Refit

5. Fit ball joint link and c astellated nut. Ensure

the ba ll joint link arm p oints up. Tighten to the

correct torque and fit new cotter pin.

6. Align anti-roll bar to ball joint links.

7. Fi t bol ts , washers and rubber bushes using

new self locking nuts secure anti-roll bar to

ba ll joint links. Tighten to the correct torque .

ADDITION: SEPT. SO


6/14

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7/14

REAR SUSPENSION (64 1.....,...

SELF LOCKING NUTS

Many steering and suspension items are secured

using self locking nuts.Where self locking nutshave been removed, they MUST be replaced with

new items of the correct type.

REAR ROAD SPRING

Remove and refit

Removing

1 .

2 .

3 .

4 ._'

Loosen the rear road wheel retaining nuts.

Raise the rear of the vehicle using a suitable

hydraulic floor jack. Support the chassis on

stands and remove the wheels.

Suppo r t the rea r ax le we igh t w i th the f loo r

jack.

Disconnect the shock absorbers at one end.

5 . Pos i t ion a su i tab le co i l sp r ing compresso r

. correctly on the road spring.6 . Compress the sp r ing even ly to fac i l i ta te

removal.

7 . Lower the ax le su f f i c ien t to f ree the road

spring from the upper seat.

CAUTION: Avoid lowering the axle further than

necessary otherwise the rear brake flexible hose

wil be damaged.

8. Remove the spring retainer plate.

9. Withdraw the road spring.

10. Lift off the spring seat.

,i,:

I

Refitt ing

11. Reverse 1 to IO. Ensu re tha t the co t te r p insecuring the top shock absorber mounting is

located in the inboard hole.

REAR SHOCK ABSORBER

Remove and refit

Removing

Loosen the road wheel retaining nuts and raise

the rea r o f the veh ic le us ing a su i tab le

hydraulic floor jack.

Supp o r t the c hassis on s tands . Rem ove the

road wheels and support the rear axle weight

with the floor jack.

Remove the fixings and withdraw the shock

absorber frpm the axle bracket.

J51 l7M

REVISED: MARCH 90 1


8/14

KANGEREAR SUSPENSION

1987-90 ROVER

4. Remove upper fixings. 2. Remove excessive m u d deoosits f r o mN O T E : j 5 l lM s h o w s 1 9 9 0 M o d e l Y e a r t o pdamper fixing.

underneath the vehicle and any heavy items

from inside the vehicle that are not part of the

original equipment.

.

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.

Refitting

3. Measure the clearance between the rear axlebump pad and the bump stop rubber at the

front outer corner on both sides of thevehicle. The average clearance should be inexcess of 67mm (2.8 in). If it is less than this

figure remove the rear springs and check theirfree length against the Road Spring Data.

Replace any spring whose free length is more

than 20mm (0.787 in) shorter than the figure

given. If after replacing a spring the averagebump clearance is still less than 67mm (2.8 in),

replace the IevellinR unit.8 .

9 .

Reverse items 7 and 6 as applicable.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 NOT

designed for this purpose.

LEVELLING U N I T

Functional check

A Boge Hydromat levelling unit is located in thecentre of the red. .-.le.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 roughness

of the terrain being crossed.

If the vehicle is overloaded the unit will fail to level

fully 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.

4 .

5 .

6 .

With the rear seat upright, load 450 kg (992lb) into the rear of the vehicle, distributing the

load evenly over the floor area. Check thebump stop clearance, with the driving seat

occupied.Drive the vehicle for approximately 5 km (3miles) 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, check

the bump stop clearance again.If the change in clearance is less than 20mm(0.787 in) the levelling unit-must be replaced.

Before carrying out the checks below, verify that

the vehicle is being operated within the specifiedmaximum loading capabilities. If the levelling unit is

then believed to be at fault, the procedure below

should be followed.

1. Check the levelling unit for excessive oilleakage and if present the unit must bechanged. Slight oil seepage is permissible.

2 REVISED: MARCH 90


9/14

PO ; ; ; 1 9 8 7 - 9 0REAR SUSPENSION

.,

LEVELLINC U N I TRemove and refit

Removing

WARNING: The levelling unit containspressurized gas and must not be dismantled nor

the cas ing screws removed. Repair is by

replacement of complete unit only.

1. Raise the rear of the vehicle using a suitablehydraulic floor jack. Support the chassis on

stands.

2. Support the axle weight using the floor jack.3. Disconnect the suspension upper links at the

pivot bracket.

4 .

5 .

6 .,-7 .

8.9 .

10 .

Ease up the lower boot.

Unscrew the lower ball joint at the levellingunit push rod, using thin jawed wrenches.Remove the top bracket fixings at the cross

member.

Removing

1. Remove the levelling unit.

2. Remove the cotter pin and nut at the rear axlebracket.

Withdraw the levelling unit and top bracketcomplete.

3. Extract the ball pin from the axle bracket usingExtractor R01006.

Ease back the upper boot.Unscrew the upper ball joint at the levellingunit, using thin jawed wrenches.Withdraw the upper and lower boots and theirretaining spring rings.

A

Refitt ing

1 1 . Coat the ball pin threads with Loctite gradeCVX or suitable equivalent sealant.

12. Reverse items 1 to 10. Do not fully tighten thefixings until all items are in their fitted

position. Finally tighten to the correct. torque

(see section 06-Torque values).LEVELLING UNIT BALL JOINTS

Remove and refit

Service tools:

R01006 Extractor for axle bracket ball joint

3


10/14

RANGE

REAR SUSPENSION1987-90 ROER

.a ,4. Withdraw the pivot bracket complete with ball

joints.

5 . Unscrew the ba l l jo in t assembly fo r t he

levelling unit.

6. Remove the ball joint assembly from the axle

b r a c k e t .

RR1605M

7 .

8 .

9 .

10.

11.

R e p la c e m e n t b a l l j o i n t s a r e s u p p l i e d a s

comple te assembl ies , less f i x ings , and a re

pre-packed with grease.

The ba ll joint for the axle b rack et must not be

dismantled.

The b all joints for the levelling unit may be

dismantled and cleaned if required.

Pack the ball joint with Dextagrease GP or an

equivalent grease when assembling.

Ensure that the bal l seat ing is square in i ts

housing before refitting.

Ref i t t ing

1 2 .

13.

4

Press the knur led ba l l jo in t in to t he p ivo t

bracket.

Screw the ball joints for the levelling unit into

the mounting brackets. If the ball joints do not

s c r e w i n e a s i l y a n d f u l l y , r e m o v e a n d t h e

assemblies ensuring that the plastic seats do

not jam in the housings. Tighten to the correct

torque (see section 06-Torque values).

14 . Fit the pivot bracket complete with ball jointsto the rear axle. Tighten to the c orrect torque

(see section 06-Torque value s).

15. Fit the levelling unit.

BUMP STOP

Remove and re f i t

Remov ing

1. Rernove the fixings.

2. Withdraw the bump stop assembly.

RR 1607M

Ref i t t ing

3. Posi t ion the f ix ing bol ts in the ~101s in thechassis brackets.

4 . F+ t h e b u m p s t o p a s s e m b ly , posrtion th e _I . . . .snoulder on the car r ier to sui t tht: chassis !configuration.


11/14

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Kn l Y u tROVER lg8 REAR SUSPENSION

UPPER SUSPENSION LINK Replacing the bush

. Remove and refit 1 to 6 and 9

BUSH

Remove and refit 7 and 8

Removing

1. Raise the rear of the vehicle using a suitable

hydraulic floor jac k. Supp ort the rear of the

chassis on stands allowing the axle to be freely

suspended.

2 . R e m o v e t h e f i x i n g s , u p p e r l i n k b r a c k e t t o

fra m e .

,/

3 .

4 .

5 .-..6 .

Re m o v e t h e f ix in g s, u p p e r l in ks to p i v o t

b ra c ke t.

Withdraw the upper link complete with frameb ra c ke t.

Remove the fixing bolt.

Sep arat e link an d b ush assem bly from b rac ket.

7. Using a suitable hydraulic or bench press and

a piece of metal tubing slightly smaller than

the outside diameter of the bush, press out

the rubber mounted bushes. Ensure the steel

tubing locates on the outer edge of the bush

and not on the rubber inner.

8. Fit the replacement bush assembly centrally in

the housing.

CAUTION: When pressing in the new bushes

ensure that pressure is applied to the outer edge

01 the bush only and not to the rubber inner.

Refitting

9. Reverse 1 to 6. Do not fully tighten the fixings

until all components are in position.

10. Finally tighten all fixings to the correct torque

(See Sec tion 06 Torque Value s).

REVISED: jUl.Y 88


12/14

l-l4 REA R SUSPENSIO N RANGE * ROVERLOWER SUSPENSION LINK Replacing the bush

Remove and refit 1 to 7, 10 to 12

BUSH

Remove and refit 8 and 9Removing

1. Place the vehicle on a suitable hydraulic hoist

for accessibility.

2. Alternatively, raise the rear of the vehicle usinga suitable hydraulic floor jack and support the

vehicle using stands placed under the axle.3. Remove the link rear fixings.

R R 1 5 9 7 M / "

4. Remove the mounting bracket fixings at theside member bracket.

5. Withdraw lower link complete with mounting

bracket.6. Remove the locknut.7. Withdraw the mounting bracket from the

lower link.

6 . REVISED: JULY 88

8. 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 steel

tubing locates on the outer edge of the bushand not on the rubber inner.

9. Fit the replacement bush assembly centrally inthe housing.

CAUTION: When pressing in the new bushensure that pressure is applied to the outer edge

of the bush only and not to the rubber inner.

Refitt ing

1 0 .

1 1 .

1 2 .

Reverse items 6 and 7. Do not tighten the

locknut at this stage.Reverse items 3 to 5.

Lower the vehicle, remove the jack and allowthe axle to take up its static laden position.

Finally tighten the locknut to the correcttorque (see section 06-Torque values).


13/14

R\$ 1991REAR SUSPENSION

ANTI-ROLL BAR ASSEMBLY REAR

KEY

1. Anti-roll bar

2 . Rubber bush

3. Strap

4. Nut, bolt, washer

ANTI-ROLL BAR REAR

Remove and refit

Remove

1. Note fo r reassembly , t he pos i t ion o f rubber

bushes on the anti-roll bar.

2 . Remove the four nu ts , bo l t s and washers

securing the two bush straps.

3. Remove the nuts, bolts, washers and rubber

bushes from the ball joint links and remove

anti-roll bar.

5. Nut and washer

6. Ball joint link arm

7. Bolt and washer

8. Castellated nut and cotter pin

Refit

4. Position the rubber bushes on the anti-roll bar.Ensure the split points towards axle.

5. Fit the anti-roll bar with the two straps. Ensurethe ball joint link arms point down as shown.

Loosely fit, the bolts, washers and new nylocnuts.

6. Fi t bol t , washers and rubber bushes. Using

new nu ts f i t an t i - ro l l bar t o ba l l jo in t l inks .

Tighten to the c orrect torque.

7 . Ti g h t e n t o t h e c o r r e c t t o r q u e t h e n u t s

securing the straps.

ADDITION: SEPT. 90 7


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.:

RANGEREA R SUSPENSIO N ROVER

\ANTI-ROLL BAR BALL JOINT L INKS-REAR

..

Remove and refit

Remove

Remove the two nu ts , bo l ts , washe rs and

r u b b e r b u s h e s f r o m t h e b a l l j o i n t l i n k s a n d

lower anti-roll bar to clear links.

Remo ve co tter pin and loosen castellated nut

a few turns.

Release ball joint using special tool 1 8 C 1 0 6 3 Aas shown.

Remove castellated nut and ball joint link.

Refit

5 . F i t b a l l j o i n t l i n k a r m a n d c a s t e l l a t e d n u t .

Ensuring the ball joint link arm points down as

shown .Tigh ten to the c o r rec t to rque and f i t

new cotter pin.

6. Align anti-roll bar to ball joint links.

7. Fit bolts, washe rs and rubbe r bushes us ing

new self locking nuts secure anti-roll bar to

ba ll joint links. Tighten to the co rrect torque .

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Documents

Range Rover Manual Suspension