Member Since: 30 Oct 2011
Location: plymouth
Posts: 6525
welcome.....good reading
2nd Aug 2019 11:30 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
I was having clunking noises coming from the front of the car and the steering was not that "sharp" that it used to be, also had some rattle when hard braking was applied. So...
Decided that it is time to rebush the whole suspension system and replace all the brake discs, pads and parking brake shoes.
ATTENTION HERE!
I have now done the front right (upper / lower bushes & brakes) and... i just wanna say if there is anybody that is thinking of rebushing suspension with an ebay bushing kit and dont have an garage.. BUY WISHBONES WITH BUSHINGS PREINSTALLED!!! OK. You save time, u save ur back and propably ur marriage.
Its gonna be torching and banging (day and night)..then the front lower left bushing comes, the BIG one.. oh man.. i dont even know the right words at the moment.. just buy the whole wishbones.
In my case. I Will be doing next front left and after that the whole rear suspension.. YES i would buy them wishbones now if i could, i really would... but i already have a trunk full of bushings waiting to be installed.. HD stuff.. yaay!... At least saved some money...
Okey, next some photos i took from the process. Enjoy.
NEEDED:
-Tools, lots of.
-Huge hammer
-Blow torch
-Protein snacks and gallons of coffee
-Bushes and bolts
-Sawzall + cutting oil to save blades
First things first, find a good spot.
Here it starts. Hub nut was tight, had to use torch to get it loose.
Mark the lower arm bolts.
Was having fun with the torch a multiple times!
Then fun stopped... Front upper right, the bolt was almost behind the air strut.. ****. It took some time to get out.
Lower arm bolt was seized, no worries. Milwaukee did the job.. actually used a cutting oil with it and did all the needed cuts in the whole process with using only one blade!... remember to install battery before starting to cut, makes things easier.
Poor bolts.
Arms and the hub.
Drill, cut & bang.
Clean the bushing slot well before pressing a new one, otherwise u will regret it.
Looks easy, it wasnt. Needed a protein snacks to keep my muscles going.
Ever seen a bush this size? Me either. Gloves are atleast size 10. BUY WISHBONES WITH BUSHES.
Installing new balljoints were actually the easiest part of the job.
All the bushings and balljoints are in place.
Old tierod vs. New tierod.
Did not count how many sunsets went by. I kept torching and banging.
Brakes done.
Job done.
Next i will do the front left and then start working with the rear suspension and will keep u guys updated how it goes.Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
Last edited by Loco02230 on 19th Feb 2020 10:06 am. Edited 5 times in total
18th Feb 2020 11:37 pm
LeighW D3 Decade
Member Since: 31 Jan 2006
Location: Brisbane, AUS
Posts: 916
Well Loco02230 because of the cold weather and difficult conditions (we only get down to 5-6°C here) I think you are doing a great job. Congratulations on persevering with the individual bushes replacement but I can appreciate why you remind everyone how much easier the job would be with the new wishbones instead.
Well done and good informative photography!LeighW
The old girl is on her third engine...
* first ran a bearing (design failure in original engine)
* second had a failure of the water outlet on top of the engine (pls check yours)
19th Feb 2020 9:28 am
ClassikFan
Member Since: 02 Nov 2016
Location: Surrey
Posts: 1027
Good work Loco, great to see lots of pics.Just 'cause you got the power... that don't mean you got the right.
19th Feb 2020 1:29 pm
Moo D3 Decade
Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13899
Good effort and good write up. New Defender L663 110 SE (known as Noddy!)
Sold Volvo XC90 R-Design (known as Basil)
Sold - D4 HSE (Known as Gerty)
No longer the Old Buses original owner
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control
19th Feb 2020 1:57 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
UPDATE:
Just finished doing a complete rebushing to the front left wishbones (driver side) + replaced the worn cv axle (atleast the rubber boots were shot).
The key to easily remove the front upper wishbones seems to be by removing all the wheel arch panels. Atleast this is must when doing the driver side which holds the webasto just behind the heat cover so there is no room even push the heat cover further to get more room like what u can do in the passenger side.
Also the cv axle boots were shot so i replaced the whole axle. Didnt know that it can be that tight... You do need a long pry bar and a hammer (yes the most important tool to fix this car), that way i managed to get it out. First tried gently... nothing... then more force (could hear the car laughing)... nothing... then hammering like no tomorrow... got it out. Installing the new axle, gently push it to the place...
Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
22nd Feb 2020 3:12 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
So.. the rear suspension rebuild is done!
After many days of hammering, hacksawing, painting and swearing got it done.. it could have been little bit easier job but again the finnish weather added the extra salt to the job. Sometimes it did rain, sometimes it did rain even more.
Starting point.
After hacksawing and hammering...
Had to order new backplates. The old ones were badly rusted.
Replacing the ARB bushings was a pain in the *** job as the bolts were seized and the size of the working area is limited. Had to use nut remover tools to get that seized bolt out.
Added rust converter + hammerite to the wishbones:
While i was at it, decided to replace the wheel bearings too.
New backplates, bushings and bearings installed.
Installed new epb shoes and replaced most of the fittings. Old shoe mechanism were rusted and stuck. No wonder why my epb module didnt function properly
All Done. (Photo from other side, yes.. did both sides)
NOT REALLY... When i was putting the wheels back to the car, i saw something leaking from the rear end. Closer look revealed that the leak was coming from those rusty brake lines that join to the flexi pipes. So... went and bought a flaring tool so i could join the new nickel copper pipes to the original LR steel pipes that goes under the drivers side just behind the heat shield.. (despite the photo, i replaced both pipes)
That was certainly a messy job as i couldn't get the brake fluid stop from leaking when i was making new flares under the pipes.. I used bubble flares to connect the new copper nickel pipes as i saw that LR used that type of flares to connect the old steel pipes to flexis.
After all were done, i went for a test drive. Must admit that the ride quality got a lot better after all the bushings got replaced. It might be that many of them were original ones fitted in 2005... so.. no wonder!Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
25th Aug 2020 5:55 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
Oh well... Another breakdown happened yesterday. Suddenly the car lost power when i was accelerating, actually kinda same scenario that happened little bit over a year ago and back then it made me suspect the fuel pump so it got replaced.
Car cranks with no problem, battery charged to 12.5V but still no fuel from the schrader valve or sound coming from the pump, so tomorrow have to test the pump with multimeter and using jumper over the pump relay (R8). Saw someone writing about problematic connector somewhere in the OSF Wheel arch? ...and the other one top of the tank will be investigated. So those are my first suspects at the moment as the pump is only 1 year old and German made :)Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
4th Sep 2020 4:04 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
Quick update.
Tested the fuel pump using a jumper wire over the relay. Works. Ordered a new relay and replaced the faulty one, yaay! 5€ fix and the beast is back on the road!
Part number is (if someone is interested): YWB500060 (40A), R8 in the engine fuse box.Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
Last edited by Loco02230 on 3rd Oct 2020 9:11 pm. Edited 1 time in total
30th Sep 2020 7:07 pm
JohnnyNapalm
Member Since: 14 Jul 2017
Location: Ramsey
Posts: 184
Following your updates with interest. Thanks for posting. Cheers
30th Sep 2020 7:46 pm
ianm27
Member Since: 02 Jun 2016
Location: Hertfordshire
Posts: 2154
Great write up and pics Loca and fair play doing all that work yourself
Got to be one of the cheapest fixes
Loco02230 wrote:
5€ fix and the beast is back in the road!
Uncle Ray's spare wheel protector
Limo Tint
Blackvue front & rear dashcam
Cruise control switch pack
Bodsy's remote for FBH
1st Oct 2020 12:54 pm
Loco02230
Member Since: 03 Dec 2018
Location: Espoo
Posts: 26
Today the car passed its MOT!
Knowing that i had replaced every bushing in the suspension, i was more worried about the handbrake adjustment (really i was worried about everything...). Well the inspector said everything is like it should be so big thanks to Bodsy for the brake bible!
Thought i'd suprise my D3 and replace all the original interior bulbs with led ones and also give a good clean with a cleaning wipes from ArmorAll. Tho i can still smell the burning bushing in the control arm before banging them out with a hammer in a rainy sunday morning in my backyard... oh well.. NEXT: Time to enjoy the ride while it works.
Front dome light-6pc
Rear dome light-3pc
Trunk light-1pc
Door light-4pcs
Footwell light-2pc
License plate light-2pc
Side light-2pc
Extra light-3pc
Really wanted to get away from the smell of the tools and chemicals i had stored in my trunk when i did the suspension rebuild. These wipes did the trick, other is for plastics and other is for the leather seats. They have a strong fragrance that will last long.
Land Rover Discovery 3 2006 HSE 2.7 Zermatt Silver
"It's not leaking oil, it's sweating POWER!
DIY Mechanic (Destroy It Yourself)
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