Front axle assembly (Discovery 3)

Special tool

Ball Joint Puller 205-754

Removal

All cars

1.

CAUTION: Do not work on a vehicle supported solely by a jack. Always place reliable supports under the vehicle.

Raise and support the vehicle.

2. Disconnect the ground cable from the battery. For more information, refer to Specification

3. Remove the front wheels.

4. Remove the axle boot. For more information, refer to Axle Tube (47.10.42)

5. Remove the front axle crossmember. Unscrew the four bolts.



6. Disconnect the left brake hose bracket from the steering knuckle. Remove the bolt.



7.

CAUTION: Do not damage the ball joint boot. Damage to the protective boot will result in premature failure of the joint.

Using a special tool, disconnect the ball joint of the left tie rod end from the steering knuckle. Unscrew and discard the nut.



8.

CAUTION: Do not damage the ball joint boot. Damage to the protective boot will result in premature failure of the joint.

CAUTION: Excessive deflection may damage the lower control arm ball joint. The steering knuckle must be supported at all times. Do not allow the steering knuckle to hang on the lower control arm. Failure to do so may result in vehicle damage.

Using a special tool, disconnect the ball joint of the left upper arm. Unscrew and discard the nut.



9. Disconnect the left axle shaft from the axle assembly.

• Remove the snap ring and discard it.
• Using a suitable clamp, suspend the left axle shaft.

10.

CAUTION: Mark the position of the propeller shaft flange relative to the pinion flange.

Disconnect the propeller shaft from the drive flange on the front axle.

• Remove 6 bolts and washers. Discard bolts.
• Using a suitable clamp, secure the driveshaft end plate.

11.

CAUTION: Before disconnecting or removing any components, ensure that the area around the mating surfaces and connections is clean. To avoid contamination of the system, cover all open connections.

Disconnect the ventilation line. Release the clamp.



Cars manufactured before 02.2007.

12.

NOTE: If a new bridge is installed, a new vent line must also be installed.

Remove the ventilation line from the front of the bridge and discard it. Release it from the three clamps.





All cars

13. Using a transmission jack, support the front axle assembly.

14. Using outside help, remove the front axle assembly.

• Remove and discard the three rear axle mounting bolts.
• Remove the front axle mounting bolt.

Installation

All cars
1. Using outside help, install the front axle assembly.

2. With assistance, align and secure the front axle assembly.

• Tighten the M14 bolt to 105 Nm.
• Tighten the three new front axle mounting bolts to 80 Nm, then tighten the bolts an additional 60 degrees.

Cars manufactured before 02.2007.

3.

NOTE: If a new bridge is installed, a new vent line must also be installed.

Install the new ventilation line in front of the bridge. Secure with clamps.

All cars

4. Connect the ventilation line.



5.

NOTE: New bolts must be installed.

Secure the cardan shaft to the drive flange in front of the axle.

• Remove and discard the clamp.
• Step 1: Tighten the bolts to 45 Nm.
• Step 2: Tighten the bolts another 90 degrees.

6. Install a new snap ring on the left axle shaft. Remove and discard the clamp.

7.

NOTE: Do not fully insert the axle shaft until the oil seal guard has been removed.

Attach the left axle shaft to the axle assembly.

• 1) Open the axle shaft seal protection and install the axle shaft.
• 2) Release the axle seal protector from the axle seal.
• 3) Remove the axle shaft seal guard.
• 4) Install the axle shaft completely.
• 5) Make sure the snap ring is fully seated and holds the axle shaft.

8.

NOTE: Screw on a new nut.

Attach the left upper control arm to the steering knuckle. Tighten the nut to 70 Nm.

9.

NOTE: Screw on a new nut.

Connect the left tie rod end ball joint to the steering knuckle. Screw on a new nut and tighten it to 76 Nm.

10. Install the left brake hose bracket to the steering knuckle. Tighten the bolt to 22 Nm.

11. Install the front axle crossmember. Tighten the four bolts to 115 Nm.

12. Install the axle liner. For more information, refer to Axle Tube (47.10.42)



13. Install the wheels. Tighten the wheel nuts to 140 Nm.

14. Connect the ground cable to the battery. For more information, refer to Specifications