Discovery 2. Manual — part 597
STEERING
REPAIRS
57-37
10. Lubricate new 'O' rings for PAS pipes with
clean PAS fluid.
11. Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm 16 lbf.ft).
12. Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
13. Remove centralising bolt from steering box.
14. Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
15. Remove stand(s) and lower vehicle.
16. Connect battery earth lead.
17. Fit battery cover.
18. Refill cooling system.
ADJUSTMENTS, Drain and refill.
19. Bleed PAS system.
20. Centralise steering linkage
Steering linkage - centralise.
Seal - input shaft - steering box
$% 57.10.16
Remove
1. Remove steering box:
l
l
l
For RHD diesel models:
2. Secure steering box in vice.
3. Remove circlip and extract oil seal from
steering box. Take care not to damage
surface of the shaft.
Refit
1. Clean oil seal recess and input shaft.
2. Lubricate new seal with clean PAS fluid.
3. Fit seal using LRT-57-503.
4. Fit circlip.
5. Fit steering box.
l
l
l
For RHD diesel models:
STEERING
57-38
REPAIRS
Seal - output shaft - steering box
$% 57.10.17
Remove
1. Remove steering box:
l
For V8 models:
l
l
2. Secure steering box in vice.
3. Release lock washer from drop arm nut.
4. Loosen but do not remove nut securing drop
arm.
5. Using LRT-57-012, release drop arm.
6. Remove nut and discard lock washer.
7. Remove drop arm.
8. Mark position of rack adjuster.
9. Remove Allen screw securing rack adjuster
and loosen adjuster one turn.
10. Remove 4 bolts securing output shaft assembly
and remove output shaft assembly. Remove
and discard 'O' ring from end cover.
11. Remove seal shield and circlip.
12. Remove seal and spacer.
STEERING
REPAIRS
57-39
Refit
1. Clean seal recess, output shaft, end cover and
mating face.
2. Lubricate new end cover 'O' ring with clean
PAS fluid. Fit 'O' ring to end cover.
3. Position output shaft, fit bolts and tighten to 88
Nm (65 lbf.ft).
4. Tighten rack adjuster one turn, align marks and
secure with Allen screw.
5. Lubricate new output shaft seal with clean PAS
fluid.
6. Fit seal using LRT-57-504.
7. Fit spacer, circlip and seal shield.
8. Clean drop arm and steering box splines.
9. Ensure steering box is in the central position.
Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).
10. Secure lock washer to drop arm nut.
11. Fit steering box.
l
For V8 models:
l
l
Pump - power steering - V8
$% 57.20.14
Remove
1. Remove auxiliary drive belt.
REPAIRS, Belt - auxiliary drive.
2. Remove cable tie securing harness to air intake
hose.
3. Loosen 3 clips securing air intake hose, release
and remove hose.
Note: Pre 03 MY air intake hose illustrated.
4. Models with ACE: Remove 3 bolts securing
ACE pump, release pump and position aside.
STEERING
57-40
REPAIRS
5. Models with A/C: Disconnect A/C compressor
multiplug. Remove 4 bolts securing A/C
compressor, release compressor and position
aside.
6. Remove 3 bolts securing PAS pump pulley and
remove pulley.
7. Position tray to catch spillage, release PAS
pump pressure pipe.
8. Remove clip and release PAS pump inlet hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
9. Remove jockey pulley.
10. Remove bolt securing oil cooling pipe bracket
and release bracket from housing.
11. Remove two bolts securing PAS pump.
12. Remove 4 bolts and one nut securing auxiliary
housing. Pull housing forward and release
PAS pump. Remove PAS pump.
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