Front Suspension Land Rover Range Rover L322

SPECIFICATIONS

TORQUE SPECIFICATIONS

+ New nut/bolts must be installed

Scheme 1

The front suspension on 2007 model year vehicles features a common tubular stabilizer bar across all engine variants.

The suspension arms have been designed for maximum ground clearance. Suspension geometry can be adjusted via the strut top mount for camber and on the steering rack track rod ends for toe-in.

The following wheel travels are shown for on road and off-road vehicle operation. The difference between the two operating conditions is a result of operation of the air suspension front cross-link valve. When the cross-link valve is opened, the suspension travel is as given for off-road wheel travel. When the cross-link valve is closed the suspension travel given for on road applies.

The off road mode wheel travel is

1. 175 mm bump
2. 95 mm rebound
3. This gives a total of 270 mm off road suspension travel.

The on road standard wheel travel is

1. 115 mm bump
2. 155 mm rebound
3. This gives a total of 270 mm on road suspension travel.

Note. Overall wheel travel stated above will still be achieved when both wheels are moving in parallel together.

The front suspension comprises

1. Two air spring damping struts
2. Subframe
3. Stabilizer bar
4. Stabilizer bar links
5. Suspension arms
6. Two hub assemblies.

STRUTS

The front suspension struts are a MacPherson twin tube design with the conventional coil spring replaced by an air spring. The lower end of the strut is connected to the front hub assembly with two bolts. The upper top mount is attached to the inner fender with three studs and nuts.

The top mount has a bearing installed which reduces the force required on the steering when the strut rotates. A paper gasket is fitted on the underside of the inner fender, between the inner fender and the top mount. The gasket prevents the ingress of dirt and moisture into the bearing. When the strut is removed, this gasket must be replaced with a new item to maintain the performance of the bearing and care must be taken to ensure that the gasket is correctly positioned.

The damper functions by restricting the flow of hydraulic fluid through internal galleries within the damper. A damper rod moves axially within the damper. As the rod moves, its movement is limited by the flow of fluid through the galleries thus providing damping of undulations in the terrain. The damper rod is sealed at its exit point from the damper body to maintain fluid within the unit and to prevent the ingress of dirt and moisture. The seal also acts as a wiper to keep the rod outer diameter clean.

Note. The dampers fitted to TDV8 vehicles differ to the dampers fitted to petrol vehicles to compensate for the extra weight and handling characteristics of the vehicle.

The air spring is fitted on the upper part of the strut. Within the strut module the air spring elements comprise a top plate assembly, an air bag and a base piston. The air bag is attached to the top plate and the piston with a crimped ring. The air bag is made from a flexible rubber material which allows the bag to expand with air pressure and deform under load. On the side of the top cap is a connector which allows for the attachment of the air hose from the cross-link valve. The piston is made from plastic and is shaped to allow the air bag to roll over its outer diameter.

TDV8 and supercharged vehicles also feature mass attached to the top mount. The mass has no function with the vehicle suspension but is fitted to improve NVH produced by the braking system.

SUBFRAME

The subframe is fabricated from steel tubing to provide a robust platform for the mounting of the suspension and engine. The subframe is attached to the vehicle body via six mountings.

The subframe fabrication provides accurate location for the suspension components and the steering rack. Additional brackets allow for the attachment of the height sensors and the engine mountings. The stabilizer bar is attached across the rear of the subframe and is mounted in flexible bushes which are secured with 'D' shaped clamp plates.

STABILIZER BAR AND LINKS

The stabilizer bar is fabricated from 31 mm diameter, spring steel tube with a 5.5 mm wall thickness. The stabilizer bar operates, via a pair of links, from a bracket mounted on each strut.

The stabilizer bar is attached to the rear of the subframe with two bushes which are bonded to the bar and cannot be removed. Clamp plates are pressed onto the bushes and must not be removed. The stabilizer bar is secured to the subframe with the clamp plates which are located on studs on the subframe and secured with nuts.

Each end of the stabilizer bar is attached to a bracket on each strut via a stabilizer link. This arrangement allows the stabilizer bar to act on a 1:1 ratio with the wheel travel providing maximum stabilizer bar effectiveness. A hardened washer is fitted between the ball joint and the strut mounting plate. The hardened washer prevents the ball joint damaging the bracket, which could lead to loosening of the torque on the nut. It is important that this washer is in the correct position and the correct, hardened washer is fitted. Failure to fit the washer or using an incorrect washer will result in relaxation of the torque on the self-locking nut and damage will be caused to the stabilizer bar link and the strut.

Each stabilizer link has a ball joint fitting at each end mounted at 90° to the axis of the link. The ball joints improve the response and efficiency of the stabilizer bar. The top ball joint attaches directly to a bracket on the strut and the lower ball joint attaches to a hole in the stabilizer bar. Both ball joints are secured with self-locking nuts.

Each link must be attached to the stabilizer bar with the ball joint on the outside of the bar and the locknut facing inwards. The ball joints on the stabilizer links are not serviceable and if replacement of either is necessary, a new stabilizer link will be required.

SUSPENSION LINKS

The front suspension hub assembly is secured to the subframe via two suspension links

Lower Arm

Each lower arm is fitted with a bush which is secured with a bolt between two brackets on the subframe. The opposite end of the lower arm is fitted with a tapered ball joint which attaches to the hub assembly. The arm has a bracket on its upper face which provides for attachment of the air suspension height sensor.

Tie Rod

The tie rod is located rearward of the lower arm. The tie rod is fitted with a compliance bush which is secured with a bolt between two brackets on the subframe. The opposite end of the tie rod has a tapered hole which locates on a ball joint which is bolted to the hub assembly.

HUB ASSEMBLY

The hub assembly comprises a swivel hub, drive flange and bearing. A seal and bearing are fitted in the swivel hub and are secured with a circlip. The drive flange has the wheel studs attached to it and locates on the splined drive shaft and is secured with a stake nut.

The forged swivel hub has a vertical boss with two cross holes. This provides location for the strut assembly which is secured with bolts and nuts to the swivel hub. Two additional bosses provide location for the brake caliper.

The lower part of the swivel hub has two threaded holes which allow for the attachment of the ball joint which locates the outer end of the tie rod. A further tapered hole allows for the attachment of the lower arm ball joint.

A hole is machined at 90° to the hub bearing. This hole allows for the fitting of the anti-lock brake system (ABS) wheel speed sensor which is secured with a screw into an adjacent threaded hole. The speed sensor reads off a target which is part of the drive shaft assembly.

FRONT LOWER ARM

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Ball joint separator 205-754(LRT-54-027)

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1. Raise and support the vehicle.
2. Remove the wheel and tire.
3. Release the height sensor link.
4. Using the special tool, release the front lower arm from the wheel knuckle. Remove the nut.
5. Remove the front lower arm. Remove and discard the nut and bolt.

INSTALLATION

1. Install the front lower arm. Tighten the nut and bolt to 165 Nm (121 lb.ft). plus a further 90 degrees.
2. Secure the wheel knuckle to the front lower arm. Tighten the nut to 80 Nm (59 lb.ft).
3. Secure the height sensor link.
4. Install the wheel and tire. Tighten the wheel nuts to 140 Nm (103 lb.ft).
5. Check, and if necessary, adjust the wheel alignment.

FRONT LOWER ARM BUSHING

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Remover/installer 204-507

REMOVAL

Note. bushes must be replaced as a pair

Scheme 5

1. Raise and support the vehicle.
2. Remove the wheels and tires.
3. LH front: Release the suspension height sensor link.
4. Release the LH front lower arm. Remove and discard the bolt.
5. Using the special tools, remove the front lower arm bushes.

Scheme 6

1. Using the special tools, install the front lower arm bushes.
2. Secure the LH front lower arm. Tighten the nut and bolt to 165 Nm (121 lb.ft). plus a further 90 degrees.
3. LH front: Secure the suspension height sensor link.
4. Repeat the above procedure for the RH side.
5. Install the wheels and tires. Tighten the wheel nuts to 140 Nm (103 lb.ft).
6. Check, and if necessary, adjust the wheel alignment.

FRONT SHOCK ABSORBER

No data available.

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1. Remove the engine undershield. Refer to «Engine Undershield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .
2. Raise the front of the vehicle.
3. Remove the front wheels and tires.
4. Release the stabilizer bar links from the stabilizer bar. Remove the 2 nuts.
5. Remove the 2 heat shields from the stabilizer bar. Remove the 4 nuts. Remove the 4 bolts.
6. Support the front subframe.
7. Lower the rear of the front subframe. Loosen the 2 bolts. Remove and discard the 6 bolts.
8. Release the front stabilizer bar. Remove the 4 nuts.
9. Remove the front stabilizer bar.

1. Install the front stabilizer bar. Locate the front stabilizer bar clamps. Loosely install the nuts.
2. Secure the front subframe. Tighten the new bolts to 165 Nm (122 lb.ft). Tighten the 2 rear bolts a further 90 degrees. Tighten the bolts to 133 Nm (98 lb.ft).
3. Secure the stabilizer bar links. Tighten the nuts to 100 Nm (74 lb.ft).
4. Tighten the front stabilizer bar clamp nuts to 56 Nm (41 lb.ft).
5. Install the stabilizer bar heat shields. Tighten the nuts. Tighten the bolts.
6. Install the front wheels and tires. Tighten the wheel nuts to 140 Nm (103 lb.ft).
7. Install the engine undershield. Refer to «Engine Undershield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .
8. Check, and if necessary, adjust the wheel alignment.

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1. Raise the front of the vehicle.
2. Remove the wheel and tire.
3. Release the stabilizer bar link. Remove the nut.
4. Remove the stabilizer bar link. Remove the nut. Collect the washer.

1. Install the stabilizer bar link. Install the special washer. Tighten the nuts to 100 Nm (74 lb.ft).
2. Install the wheel and tire. Tighten the wheel nuts to 140 Nm (103 lb.ft).

REAR LOWER ARM

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Ball joint separator 205-754(LRT-54-027)

Scheme 14

1. Raise and support the vehicle.
2. Remove the wheel and tire.
3. Release the height sensor link.
4. Using the special tool, release the front lower arm from the wheel knuckle. Remove the nut.
5. Remove the front lower arm. Remove and discard the nut and bolt.
6. Using the special tool, release the rear lower arm from the wheel knuckle. Remove the nut.
7. Remove the rear lower arm. Remove and discard the bolt.

1. Install the rear lower arm. Tighten the nut and bolt to 165 Nm (121 lb.ft). plus a further 90 degrees.
2. Secure the wheel knuckle to the rear lower arm. Tighten the nut to 80 Nm (59 lb.ft).
3. Install the front lower arm. Tighten the nut and bolt to 165 Nm (121 lb.ft). plus a further 90 degrees.
4. Secure the wheel knuckle to the front lower arm. Tighten the nut to 80 Nm (59 lb.ft).
5. Install the wheel and tire. Tighten the wheel nuts to 140 Nm (103 lb.ft).

REAR LOWER ARM BALL JOINT

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Ball joint separator 205-754(LRT-54-027)

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1. Raise and support the vehicle.
2. Release the rear lower arm. Remove and discard the bolt. Using a suitable tie strap, reposition the rear lower arm to one side.
3. Remove the rear lower arm and ball joint assembly. Remove and discard the 2 Torx bolts. Remove and discard the tie strap.
4. Using the special tool, release the rear lower arm from the ball joint. Remove the nut.

1. Install the LH rear lower arm ball joint. Tighten the bolts to 60 Nm (44 lb.ft).
2. Install the rear lower arm. Tighten the nut and bolt to 165 Nm (121 lb.ft). plus a further 90 degrees.
3. Secure the wheel knuckle to the rear lower arm. Tighten the nut to 80 Nm (59 lb.ft).

REAR LOWER ARM BUSHING

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Remover/Installer 204-508

Scheme 18

1. Remove the LH rear lower arm. See «Rear Lower Arm»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension__rear-lower-arm) .
2. Using the special tools, remove the rear lower arm bushes.

Scheme 19

1. Using the special tools, install the rear lower arm bushes.
2. Install the LH rear lower arm. See «Rear Lower Arm»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension__rear-lower-arm) .
3. Repeat the procedure for the RH side.

Note. Vehicles with high performance brakes have a damper fitted to the top of each front suspension air spring. The damper is secured with high strength thread adhesive and must be replaced if the air spring is renewed.

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1. Raise and support the vehicle.
2. Remove the front road wheel.
3. Using the Land Rover approved diagnostic system, depressurize the air suspension. Refer to «Air Suspension System Depressurize and Pressurize»(/land-rover/range-rover/l322-2005-2009/remont/electronic-suspension/#vehicle-dynamic-suspension) .
4. Release the ABS sensor lead and brake line. Release from the 3 clips.
5. LH side: Release the brake pad wear sensor lead. Release from the clip.
6. Release the stabilizer bar link. Remove the nut.
7. Release the hub from the air suspension spring. Remove the 2 nuts and 2 bolts. Lower the jack.
8. Mark the fitted position of the stud to aid assembly. Remove the nut.
9. Release the air suspension spring. Remove the cap. Remove the 2 remaining nuts.
10. Remove the air suspension spring. Disconnect the air line. Remove and discard the gasket.

Scheme 25

1. Install the air suspension spring. Clean the component mating faces. Install a new gasket. Install the air line but do not tighten the union fully at this stage. Tighten the nuts to 56 Nm (41 lb.ft).
2. Tighten the air line union to 3.5 Nm (2.6 lb.ft).
3. Connect the hub to the air suspension spring. Clean the component mating faces. Fit bolts and tighten nuts to 250 Nm (184 lb.ft).
4. Connect the stabilizer link. Install the special washer. Tighten the nut to 100 Nm (74 lb.ft).
5. Secure ABS sensor lead and brake line. Secure into the 3 clips.
6. LH side: Secure the brake pad wear sensor lead. Secure in the clip.
7. Vehicles with high performance brakes: Install a new damper. Clean the component mating faces. Apply a 3 mm bead of high strength retainer STC 50554 to the thread. Tighten to 20 Nm (15 lb.ft). Install the cap.
8. Using the Land Rover approved diagnostic system, pressurize the air suspension. Refer to «Air Suspension System Depressurize and Pressurize»(/land-rover/range-rover/l322-2005-2009/remont/electronic-suspension/#vehicle-dynamic-suspension) .
9. Install the road wheel. Tighten nuts to 140 Nm (103 lb.ft).
10. Check, and if necessary, adjust the wheel alignment.

FRONT WHEEL BEARING AND WHEEL HUB

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Remover 204-509-3(LRT-60-033/5) Remover 204-509-2(LRT-60-033/2) Remover 204-509-1(LRT-60-033/1) Remover 204-509-2(LRT-60-033/2) Remover 204-509-4(LRT-60-033/6) Installer 204-509-08(LRT-60-033-10) Installer 204-509-10(LRT-60-033-12) Installer 204-509-09(LRT-60-033-11)

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1. Remove the wheel knuckle assembly. See «Wheel Knuckle»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension__wheel-knuckle) .
2. Remove the brake disc shield. Remove the 3 bolts.
3. Install the special tools to the wheel knuckle.
4. Install the special tools to the wheel knuckle.
5. Using the special tools, remove the wheel hub.
6. Remove the special tools.
7. Using the special tools, remove the front wheel bearings. Remove and discard the circlip.
8. Remove the special tools.
9. Remove the front wheel bearing inner track from the wheel hub.

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1. Locate the wheel knuckle on to the special tools.
2. Using the special tools, install the front wheel bearings. Apply suitable sealant to the bearing mating surface in the wheel knuckle for half its length. Install a new circlip.
3. Using the special tools, install the wheel hub.
4. Remove the special tools.
5. Install the brake disc shield. Tighten the bolts.
6. Install the wheel knuckle assembly. See «Wheel Knuckle»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension__wheel-knuckle) .

WHEEL KNUCKLE

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Ball joint separator 211-314(LRT-57-036) Ball joint separator 205-754(LRT-54-027) Halfshaft remover/replacer 204-506/3(LRT-60-030/3) Halfshaft remover/replacer 204-506/1(LRT-60-030/1) Halfshaft remover/replacer 204-506/2(LRT-60-030/2) Retainers - halfshaft remover/replacer 204-506/5(LRT-60-030/5)

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1. Raise the front of the vehicle.
2. Remove the front wheel and tire.
3. With assistance, remove and discard the halfshaft nut.
4. Remove the RH front brake disc. Refer to «Brake Disc - Vehicles With: High Performance Brakes»(/land-rover/range-rover/l322-2005-2009/remont/mechanical-hydraulic/#front-disc-brake) .
5. Release the RH front anti-lock brake system (ABS) sensor and wiring harness. Release the clip. Remove the bolt.
6. Loosen the RH tie rod end locking nut.
7. Using the special tool release the RH tie rod end. Remove and discard the nut.
8. RH side front: Release the suspension height sensor.
9. Using the special tool release the RH front lower arm. Remove the nut. Loosen the nut and bolt.
10. Using the special tool release the RH rear lower arm. Loosen the nut and bolt. Remove the nut.
11. Using the special tools, release the halfshaft from the wheel hub.
12. Remove the special tools.
13. Release the halfshaft from the wheel hub.
14. Remove the wheel knuckle assembly. Remove the 2 nuts and 2 bolts.

1. Install the wheel knuckle assembly. Tighten the nuts and bolts to 250 Nm (184 lb.ft).
2. Locate the halfshaft in the wheel hub. Lightly lubricate the halfshaft splines. Clean the halfshaft and wheel hub splines.
3. Using the special tool, pull the halfshaft in to the wheel hub.
4. Remove the special tool.
5. Secure the RH rear lower arm. Tighten the nut to 80 Nm (59 lb.ft). Tighten the rear lower arm nut and bolt to 165 Nm (122 lb.ft) plus a further 90 degrees.
6. Secure the RH front lower arm. Tighten the nut to 80 Nm (59 lb.ft). Tighten the lower arm nuts and bolts to 165 Nm (122 lb.ft) plus a further 90 degrees.
7. RH side front: Secure the suspension height sensor.
8. Secure the RH tie rod end. Install a new nut and tighten to 80 Nm (59 lb.ft).
9. Secure the RH front ABS sensor and wiring harness. Apply anti-seize compound to the ABS sensor. Tighten the bolt to 8 Nm (6 lb.ft) Secure in the clip.
10. Install the RH front brake disc. Refer to «Brake Disc - Vehicles With: High Performance Brakes»(/land-rover/range-rover/l322-2005-2009/remont/mechanical-hydraulic/#front-disc-brake) .
11. With assistance tighten the wheel hub nut to 420 Nm (311 lb.ft). Use a new nut. Stake the nut to the halfshaft.
12. Install the front wheels and tires. Tighten the wheel nuts to 140 Nm (103 lb.ft).
13. Check, and if necessary, adjust the wheel alignment.

DISASSEMBLY

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1. Raise and support the vehicle.
2. Remove the shock absorber and spring assembly. See «Shock Absorber and Spring Assembly»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension) . .
3. Install a suitable spring compressor in a vise.
4. Install the shock absorber and spring assembly in the spring compressor. Compress the spring just sufficiently to relieve the spring tension.
5. Remove the shock absorber. Restrain the shock absorber spindle, remove and discard the nut. Remove the upper bush rebound plate and upper bush. Remove the upper mounting assembly. Remove the dust tube and rebound plate assembly. Remove the spring aid.
6. Remove the spring from the spring compressor.
7. Clean and inspect the components for deterioration. To aid reassembly, mark the position of the rubber insulator in relation to the upper mounting plate. Remove the rubber insulator. Remove the spacer. Remove the rebound plate from the dust tube.

Scheme 49

1. Install the spring in the spring compressor. Make sure the spring is installed with the close coils positioned towards the top of the shock absorber.
2. Install the spring aid.
3. Install the dust tube. Install the rebound plate into the dust tube.
4. Install the shock absorber. Make sure the spring is correctly located in the spring seat.
5. Install the upper mounting. Install the spacer and rubber insulator, making sure the spacer drops over the stud heads and the insulator is aligned with the mark made previously. Install the upper bush and upper bush rebound plate. Install a new nut and tighten to 98 Nm (72 lb.ft).
6. Install the shock absorber and spring assembly. See «Shock Absorber and Spring Assembly»(/land-rover/range-rover/l322-2005-2009/remont/suspension-front/#front-suspension) . .

See also:
• Engine Undershield
• Air Suspension System Depressurize and Pressurize
• Brake Disc - Vehicles With: High Performance Brakes
• Specifications
• Rear Lower Arm
• Wheel Knuckle
• Shock Absorber and Spring Assembly