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How To? - Change Front Driveshaft Boots
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3
How To? - Change Front Driveshaft Boots

My D3 failed it's MOT today on a split inner CV boot Big Cry



I was quoted almost £250 for my local dealer to do the work, Shocked So I bought a OEM boot kit, which contains everything you need for £35, and replaced both boots myself, it wasn't too diffcult, (with some help from Pagan UK as a willing assistant) Thumbs Up

Shaft with nice new boots Wink



I'll add a write up and some more pictures showing how we did it - using nothing more than normal home mechanic tools soon Thumbs Up
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 
 
Post #68713328th Aug 2010 10:53 pm
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dsd1036
 


Member Since: 27 Feb 2010
Location: Surrey
Posts: 2692

United Kingdom 2005 Discovery 3 TDV6 S Auto Zambezi SilverDiscovery 3

nice one Steve!

You must of nearly done those final 4k to reach 105k have you?

Cant wait to read your write up on changing cam and ancillary belts!

rgds

DSD

Darrell Mr. Green
  
Post #68715729th Aug 2010 6:54 am
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3

Nah, just on 102.5k at the moment, and I think Disco Mikey has already beaten me to it on a very comprehensive write up on doing the timing belt etc

http://www.disco3.co.uk/forum/topic53674.html

I'll have to find something that no one has had the courage to do I guess Rolling Eyes

Steve
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 
 
Post #68726629th Aug 2010 4:48 pm
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3

As promised, here is how I changed the drive shaft boots on my D3

You will need:-

An assistant (a BIG thanks to Pagan UK Thumbs Up )
A good trolly jack, I used a 2 ton one
Axle stand(s)
Comprehensive socket set (1/2" and 3/8" will do) as long as you have a 32mm socket for the hub nut Rolling Eyes
Various hand tools, pliers, junior hacksaw etc
Some wire, string or strong cable ties (to support the brake caliper)
Copper slip grease.
Cleaning fluid - (I used inert solvent based, but petrol would be ok, anything that does not leave a residue)
Container (to catch the diff oil)
0.61 ltr of 75W90 gear oil (I used Castrol)
Boot Kit (LR part No TDR500100)
Hub Nut (LR part No RFD500020)
Patience
Lots of cups of tea

Anyone contemplating changing the drive shaft CV boots, would also find this write up very helpful, as a lot of the initial tasks are the same http://www.disco3.co.uk/forum/topic31160.html

Start by loosening (just) the road wheel nuts, and jacking the vehicle and supporting on axle stand(s) as I was only doing the front nearside, I only lifted the one corner, then remove the road wheel.

Refer to the manual for jacking positions if your unsure Thumbs Up

Underneath, remove the sump plate, and undo the diff drain plug (3/8" socket end fits) there isn't much, just over a pint (0.61 ltr) allow the oil to drain into a suitable container, and replace the plug and tighten (or you'll forget, and then replace the sump plate. That's the only task under the vehicle Wink

With the help of your assistant, (they need to apply the brakes) undo the big nut in the middle of the hub (32mm, and I used a breaking bar with a length of scaffold pole to give some leverage) no need to completely remove it at this stage, then remove the brake caliper complete, and support out of your way, being careful not to twist or damage any of the brake hoses or wires, in particular take care of the wear sensor, as they can be quite fragile.

You should then have got this far:



I then removed the brake back plate (not totally necessary) but allows some extra room to see what you're doing !

Undo the top swivel joint, and break apart, usually a sharp strike with a hammer will be all that's needed, remove the hub nut:


(I know, the drive shaft is already out in this picture, but . . .)

Then 'just' pull out the drive shaft you may need to give it quite a sharp pull for the spring clip to release:



This is were a bence vice is handy, but a work mate would do just as well
Start to remove the boot clips at the INNER end first:



and cut the large one with a junior hacksaw:



Pull apart the CV joint, remove the circlip on the end of the splined end, and gently drift the roller bearing unit off the end of the shaft.



then clean carefully and thoroughly, it should then look similar to this:



remove the 2nd boot (outer end) in the same way, and carefully clean everything, I can't over stress making sure that everything is absolutely spotless is very important, as any grit or other debris in the bearings will reduce the life of the CV bearings, and could cause premature failure. (expensive Shocked )



once it is all nice and clean, start to reassemble, slide the outer boot on first, (a smear of grease on the shaft will help) and repack the bearing with graphite grease (pack A in the kit)



Slide on the new boot:



Slide on the 2nd inner boot:



and then repeat with the inner CV assembly, Not forgetting to replace the circlip, repack using the lithium grease (pack B in the kit)
note: the outer CV uses a graphite based grease, whilst the inner one uses a lithium based one



Now comes the tricky bit (unless you have the special tool for crimping the band clamps) as I did not have access to this tool, I had to improvise, the band has a raised section which needs to be pinched together to tension the whole band, I used a pair or pilers, which fitted nicely, and the trusty bench vice Wink



I was actually quite surprised how good a job it made, but I dare say the purists amoung you will cringe at my method. Finally you get to this stage:



The you can start the refit task, firstly clean and apply a smear of grease to the inner oil seal (LR suggest a special tool for inserting the shaft - they would !!)
Again, in the kit there is a new clip, make sure this is fitted, and slide the shaft in to the differential, I was just very careful not to pinch the seal as the shaft slid in:



Then refit the shaft into the hub, I smeared with a little copperslip incase I ever need to do this again, or change a hub bearing etc, and raise the whole hub unit to refit the top swivel joint back together:



Once this is completed, it's plain sailing to refit a new hub nut (loosely for now) and the hub back plate, brake caliper and brake hoses etc.
Then with your assistant again pressing on the brake pedal, tighten the hub nut to 350lbs/ft torque, refill the differential with oil (only 0.61 of a litre is required)
Replace the road wheel, lower to the ground and your done Thumbs Up
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 


Last edited by disco_steve on 30th Aug 2010 9:56 am. Edited 13 times in total 
Post #68727329th Aug 2010 5:03 pm
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Gareth
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Member Since: 07 Dec 2004
Location: Bramhall
Posts: 25650

United Kingdom 2013 Discovery 4 3.0 SDV6 HSE Lux Auto Fuji WhiteDiscovery 4

This post has been edited by the site administration team


Nice one Steve Thumbs Up I hope you don't mind me editing the title to make it easier to search in the future.
  
Post #68728229th Aug 2010 5:30 pm
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CJM625
 


Member Since: 21 Jun 2010
Location: Cheshire
Posts: 258

United Kingdom 2009 Discovery 3 TDV6 HSE Auto Buckingham BlueDiscovery 3

How long did that take please?
 2015 BMW i3 REX
2014 Golf GTD DSG 
 
Post #68728329th Aug 2010 5:34 pm
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3

Gareth wrote:
This post has been edited by the site administration team


Nice one Steve Thumbs Up I hope you don't mind me editing the title to make it easier to search in the future.


Not in the slightest (was still adding pictures though Laughing )
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 
 
Post #68728429th Aug 2010 5:37 pm
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Martin
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Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 17915

Wales 2006 Discovery 3 TDV6 SE Manual Buckingham BlueDiscovery 3

Fantastic write up, thanks Thumbs Up
 06 D3 SE / 15 LR D90 XS SW / 88 LR 90 Td5 / 68 BMW 2000 ti
Any issues with the site let me know! 
 
Post #68728529th Aug 2010 5:39 pm
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3

The whole job took me around 4 hours (but I had lunch and numerous tea stops, as well as taking all the pictures)

So . . I would think it could be done in approx 2 - 3 hours without all the stopping Thumbs Up

However - you can spend a LOT of time getting the drive shaft to release from the hub, I was very lucky, it came out without too much fuss and some help from Pagan UK, I have heard stories that this part alone can take an hour or more Shocked
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 
 
Post #68728629th Aug 2010 5:41 pm
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Bodsy
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Member Since: 06 Nov 2006
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United Kingdom 2007 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Great write up Steve Thumbs Up Thumbs Up

Just might want to add that people should put the circlip back on before re-assembly otherwise it could pop off Thumbs Up
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Post #68728729th Aug 2010 5:43 pm
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disco_steve
 


Member Since: 25 Aug 2009
Location: Are you sure this is the M5 ?
Posts: 1498

England 2006 Discovery 3 TDV6 HSE Auto Arctic FrostDiscovery 3

Bodsy wrote:
Great write up Steve Thumbs Up Thumbs Up

Just might want to add that people should put the circlip back on before re-assembly otherwise it could pop off Thumbs Up


Cheers Bodsey, well spotted, and duly amended, also added the other inner 'clip' which I'd omitted to mention, and have edited a few bits here and there to (hopefully) make it read a bit better Rolling Eyes Whistle

(this is my first full write up - that's my excuse, btw, is there an easy way to add your pictures from the galley, or is it one at a time ?)

p.s. you would have a set of timing pins by any chance, as that 's the next major job Whistle

Cheers, Steve
 Never get mad - get even !!

06 D3 now gone to family member and still going strong at 265k

previous vehicles:
04 D2 TD5 - (clocked 189k from new)
52 X-Trail 2.2 SVE
various euro boxes ! 
 
Post #68729929th Aug 2010 6:03 pm
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Bodsy
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Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21335

United Kingdom 2007 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Sorry no pins here. Can't remember who recently did theirs, but I'll need some in about 40,000 miles Laughing
 Bodsys Brake Bible

D4/D3 Remote FBH heat kits
BAS Remaps/ EGR Blank
Transmission Flush
Software updates/enabling


Clock/ SNOTM /3Flash / 4x4Info /BT Update /Service Reset/Error Codes / Gearbox Reset
See It Here 
 
Post #68733029th Aug 2010 8:01 pm
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pa28pilot
 


Member Since: 08 Mar 2009
Location: Lancashire
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United Kingdom 2005 Discovery 3 TDV6 S Manual Adriatic BlueDiscovery 3
Boot cover

Great write up any chance of putting it in wiki so it can be accessed in the future.
Cheers Thumbs Up
 Don't be blinkered vision, see the world in colour.  
Post #68734529th Aug 2010 8:30 pm
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trynian
 


Member Since: 03 Sep 2009
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United States 2006 LR3 4.0 V6 Petrol SE Auto Atacama SandLR3

Yes, good work.
  
Post #68740030th Aug 2010 1:53 am
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PaulP
 


Member Since: 04 May 2007
Location: Barcelona
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Spain 2006 Discovery 3 TDV6 SE Auto Buckingham BlueDiscovery 3

Thanks Steve - excellent write-up Bow down Bow down Thumbs Up

disco_steve wrote:
refill the differential with oil (only 0.61 of a litre, and when you see a trickle from the filler hole, that's enough (assuming the vehicle is now on the level)

I thought that the front diff, rear diff and transfer were filled by volume only....I mean that the trick of filling until oil starts to trickle out of the filler hole was only applicable to the auto box. Question
 2006 Discovery 3 TDV6 SE Auto Buckingham Blue
2007 Golf GT DSG 
 
Post #68745230th Aug 2010 9:27 am
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