Suspension - Revised Front Shock Replacement
No: 60/02/05/NASFGN LT204
Ref:
Issue: 1
Date: March 16, 2005
Revised Front Shock Replacement Procedure and Times
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) All
SITUATION:
REVISED REPLACEMENT PROCEDURE
This bulletin has been issued as the result of a change in the service repair time and the process for changing the front shock absorbers on Discovery Series II models. The revised procedures will be updated on GTR at the next opportunity.
RESOLUTION:
FOLLOW NEW PROCEDURES AND SRO TIMES
Refer to the Service Procedure and Warranty sections of this bulletin for updated shock absorber replacement times and processes. The procedure optimizes replacement times and replaces the published information on GTR Section 60.30.02.
PARTS INFORMATION:
As per Microcat Parts Catalog
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
NOTE:
The two new SRO numbers announced in this bulletin are unique for single shock absorber replacement on each side of the vehicle. The new processes outlined in the bulletin save some time so the individual shock absorber replacement time previously used for both sides of the vehicle (60.30.02) is reduced from 0.40 hours. Replacement of both shock absorbers (60.30.01) remains unchanged at 0.60 hours.
REPAIR PROCEDURE
REMOVE AND REPLACE LEFT FRONT SHOCK ABSORBER (60.30.13)
Remove
NOTE:
GTR lookup sequence is as follows: GTR Home > NAS > Service Information/LT Discovery Series II/2004 > Workshop Manuals (temporary test style > "CHARGING AND STARTING/REPAIRS" > "Battery" link.
1. Refer to GTR Workshop Manual Section 86.15.01 and disconnect battery ground lead.
2. Position the mass air flow sensor wiring harness aside as follows: (Figure 1)
^ Disconnect the connector.
^ Release the harness securing clip.
3. Position the air intake hose aside as follows:
^ Release the hose clamp securing the air intake hose to the throttle body.
^ Release the two spring clips.
4. Remove the bolt securing the air conditioning (AC) pipe to the body. (Figure 2)
5. Remove the bolt securing the top of the shock though the shock turret. (Figure 3)
6. Remove the four nuts securing the shock turret base to the chassis. (Figure 4)
7. Compress the shock downwards. (Figure 4)
CAUTION:
Care must be taken to avoid damage to the AC and brake pipes.
8. Release the shock turret from the chassis and maneuver out from the engine bay.
9. Remove the two bolts securing the bottom of the shock to the axle. (Figure 5)
10. Remove the shock.
Install
1. Position shock absorber for installation and align the lower bolt holes.
2. Install the bolts securing the shock lower mounting and tighten to 45 Nm (33 lbf. ft). (Figure 5)
3. Maneuver the shock turret into position and align the shock top mounting in the shock turret.
4. Install the bolt securing the top of the shock to the shock turret, but do not tighten.
5. Install the retaining nuts securing the shock turret to the chassis and tighten to 23 Nm (17 lbf. ft).
6. Tighten the shock upper retaining bolt to 125 Nm (92 lbf. ft).
7. Install the bolt securing the A/C pipe to the body and tighten 10 Nm (7 lbf. ft)
8. Install and secure the air intake hose.
9. Connect the wiring harness to the mass air flow sensor and secure the wiring harness clip.
10. If repairs are complete, refer to GTR Workshop Manual Section 86.15.01 and connect the battery ground lead.
REMOVE AND REPLACE RIGHT FRONT SHOCK ABSORBER (60.30.05)
Remove
1. If not previously performed, refer to GTR Section 86.15.01 and. disconnect battery ground lead.
2. Release coolant reservoir and position aside. (Figure 6)
3. Remove the bolt securing the top of the shock though the shock turret. (Figure 7)
4. Remove the four nuts securing the shock turret base to the chassis.
5. If vehicle is equipped with active cornering enhancement (ACE) perform the following: (Figure 8)
^ Remove the retaining nut securing the pipe support bracket to the shock turret.
^ Release the ACE pipe bracket from the shock turret/chassis studs and position aside.
6. Release the two wiring harness connectors from the body to allow access. (Figure 10)
7. Release the clip securing the electrical harness to shock turret. (Figure 10)
8. Compress the shock downwards.
CAUTION:
Care must be taken to avoid damage to the ACE pipes if equipped.
9. Release the shock turret from the chassis and maneuver out from the engine bay.
10. Remove the two bolts securing the bottom of the shock to the axle. (Figure 11)
11. Remove the shock absorber.
Install
1. Install shock and align the lower bolt holes.
2. Install the bolts securing the shock lower mounting and tighten to 45 Nm (33 lbf. ft).
3. Maneuver the shock turret into position and align the shock top mounting in the shock turret.
4. Install the clip securing the electrical harness to the shock turret.
5. Install the bolt securing the top of the shock to the shock turret, but do not tighten at this stage.
6. Install wiring harness connector to body.
7. Install ACE pipe bracket to the shock turret/chassis studs.
8. Position the ACE pipe bracket to the turret.
9. Install the retaining nut securing the ACE pipe support bracket to the turret and tighten to 10 Nm (7 lbf. ft).
10. Install the retaining nuts securing the shock turret to the chassis and tighten to 23 Nm (17 lbf. ft).
11. Tighten the shock upper retaining bolt to 125 Nm (92 lbf. ft).
12. Install the coolant reservoir.
13. If repairs are complete, refer to GTR Workshop Manual Section 86.15.01 and connect the battery ground lead.