Discovery 2. Manual — part 177
STEERING
REPAIRS
57-43
Steering column assembly and lock
$% 57.40.01
Remove
1. Remove steering column intermediate shaft.
intermediate and universal joint - steering
column.
3. Open fascia lower access panel.
4. Remove steering column nacelle.
5. Disconnect multiplug and illumination bulb
from passive coil and remove passive coil.
6. Disconnect 2 multiplugs from wiper switch
assembly.
7. Disconnect 2 multiplugs from light switch
assembly.
8. Loosen screw and remove switch assembly.
9. Disconnect ignition switch multiplug.
10. Disconnect multiplug from ignition switch
housing.
11. Release harness from column clip.
STEERING
57-44
REPAIRS
12. Remove 4 nuts securing steering column
assembly to fascia rail and remove steering
column assembly.
13. Remove rubber boot from steering column
assembly.
14. Position steering column assembly in a vice.
15. Remove 2 screws and remove ignition switch.
16. Remove cable tie and remove multiplug from
ignition switch.
17. Centre punch or drill out steering lock shear
bolts.
18. Remove steering lock
Refit
1. Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
2. Insert starter key, check operation of steering
lock and that key turns freely.
3. Tighten shear bolts fully and shear heads off.
4. Position ignition switch to column, fit and
tighten screws.
5. Position multiplug to switch and secure with
new cable tie.
6. Fit rubber boot to column.
7. Remove column from vice.
8. Position steering to fascia rail fit nuts and
tighten to 22 Nm (16 lbf.ft).
9. Secure harness to column clip.
10. Position rubber grommet.
11. Close access panel and secure turn buckles.
12. Connect ignition switch multiplugs.
13. Position column switch and tighten clamp
screw.
14. Connect column switch multiplugs.
15. Position passive coil, connect multiplug and
illumination bulb.
16. Fit steering column nacelle.
17. Fit rotary coupler.
18. Close fascia lower access panel.
19. Fit steering column intermediate shaft.
STEERING
REPAIRS
57-45
Shaft - intermediate and universal joint -
steering column
$% 57.40.22
The intermediate shaft has a red indicator clip
fitted which must be inspected at service, and
after the vehicle has been subject to an impact.
If the clip is not present or is not fully seated
against the clamp plate, a new assembly must be
fitted.
Remove
1. LHD diesel: Loosen 2 clips securing
intercooler to turbocharger hose. Place hose
aside.
2. Remove bolt securing intermediate shaft to
steering column.
3. Remove bolt securing intermediate shaft to
universal joint.
4. Universal joint: Remove the bolt securing the
universal joint to the steering box.
STEERING
57-46
REPAIRS
5. Ensure steering wheel is in the straight ahead
position and fit centralising bolt to steering box.
Remove the key from the ignition switch
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
6. Intermediate shaft: Slide the intermediate
shaft upwards, release from the universal joint
and remove intermediate shaft from the
steering column.
7. Universal joint: Slide the intermediate shaft
upwards, release from the universal joint and
remove universal joint from the steering box.
Refit
1. Clean and inspect splines for wear and
damage.
2. Intermediate shaft: Locate intermediate shaft
on steering column and engage with universal
joint. Ensure splines are fully engaged and bolt
holes aligned.
3. Universal joint: Locate universal joint on
steering box and engage in intermediate shaft.
Ensure splines are fully engaged and bolt
holes aligned.
4. Fit bolts securing intermediate shaft to
universal joint and tighten to 25 Nm (18 lbf.ft).
5. Intermediate shaft: Fit bolts securing
intermediate shaft to steering column and
tighten to 25 Nm (18 lbf.ft).
6. Universal joint: Fit bolts securing universal
joint to steering box and tighten to 25 Nm (18
lbf.ft).
7. LHD diesel: Connect hose to turbocharger
and intercooler and secure the clips.
8. Fit ignition key, remove steering box
centralising bolt and check that steering wheel
is in the straight ahead position.
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