Suspension overhaul...

[DJL9999]

Well look what turned up 5 business days from order from LRDirect.. would have been here Monday but I guess Santa got in the way [emoji319][emoji23] .... one box ordered a day later to split order but I guess now the work begins...
https://www.aulro.com/afvb/images/imported/2017/12/683.jpg

[DiscoJeffster]

Which set did you order? OEM, Original Equipment, Land Rover?
I just did mine, including a Hitachi compressor rebuild. Enjoy the front struts and getting to the rearward too bolt! It’s joy.

[DJL9999]

Which set did you order? OEM, Original Equipment, Land Rover?
I just did mine, including a Hitachi compressor rebuild. Enjoy the front struts and getting to the rearward too bolt! It’s joy.

Hi DiscoJeffster - I ordered a mix of parts but the arms are OEM - all parts LRD Workshop approved 2 Year warranty (my thought process was it must be a good part) also some LR parts where the price wasn't too far away! everything looks great from initial inspection and the last of the boxes rocked up.. so I have everything now. I did the compressor last year and it has been going strong, doing the valve blocks this round. actually the only parts I haven't done yet are the airbags..

[DiscoJeffster]

Hi DiscoJeffster - I ordered a mix of parts but the arms are OEM - all parts LRD Workshop approved 2 Year warranty (my thought process was it must be a good part) also some LR parts where the price wasn't too far away! everything looks great from initial inspection and the last of the boxes rocked up.. so I have everything now. I did the compressor last year and it has been going strong, doing the valve blocks this round. actually the only parts I haven't done yet are the airbags..

Ah sorry. I couldn’t see the photo originally and just assumed it was struts you’d ordered. You look to have your work cut out for you with that lot!

[DJL9999]

All arrived 5 BU days from ordering! It’s a pile of parts now.. also in the mix - new rear tailgate locks, fuel door lock, bonnet / rear door struts and rear mud flaps.. Christmas present to the disco for all her hard work!

https://www.aulro.com/afvb/images/imported/2017/12/687.jpg

Pretty excited if you can’t tell. Hahaha. [emoji3]

[DiscoJeffster]

All arrived 5 BU days from ordering! It’s a pile of parts now.. also in the mix - new rear tailgate locks, fuel door lock, bonnet / rear door struts and rear mud flaps.. Christmas present to the disco for all her hard work!

https://www.aulro.com/afvb/images/imported/2017/12/687.jpg

Pretty excited if you can’t tell. Hahaha. [emoji3]

I changed my rear door actuator this week given their propensity to fail, as I did with the alternator and brake light switch. I prefer to avoid issues and replace early rather than get caught out, as it seems you do too!

[vee8auto]

.....Pretty excited if you can’t tell. Hahaha. [emoji3]

that will wear off.

Heads up, just in case you werent aware, you will have to crack into the rear brake lines to replace the control arms.
Have some brake fluid handy.

[DJL9999]

Cheers thanks I read that last night. Might slip the calliper off or do that.

[DJL9999]

Finally got a day to finish it all off! All up two and a bit days with a heap of other minor repairs to locks and worn parts. Off to a 4 wheel and steering alignment tomorrow - cant wait to feel the ride.

https://www.aulro.com/afvb/images/imported/2018/01/172.jpg

[DiscoJeffster]

So was that every arm and bolt replaced, plus ????
Massive amount of work there.

[DJL9999]

Yep all bolts, nuts, arms and rubbers (rear anti roll bar rubbers were easy in the end) - it was a bit of a job :) especially on stands and really rough pebble drive way :) time for a beer [emoji481]

[Globetrotter]

Good Job, looks like all bolts came undone. Were bushes worn or was this a preventive blow so you get another 10 years out of the suspension etc.
I noticed that you had the steering rods in there, how much play was there in the old ones.
I have a 2008 model purchased end of 2007 so age is around the same.
Could you give a ball park of costs or even a parts list for other poor unfortunates who will need to do this.
It is sensible to replace all nuts and bolts. Did you do any brake updates?

[DJL9999]

Too easy see below - the parts from LRDirect I split the order up into three so as not to pay extra duty etc - cost more in fright ~$550 total but better than $400 plus 10% plus unknown DHL duty etc.. so I went with the known option it all took 5 BU days to arrive. the main reason was that I had a knock when turning in and over bumps and the bushes you could see were cracked and in need of replacement - maybe 40K ago - I'm on about 220k odd on her now.. after going around Australia. My steering arms didn't feel warn at all.. and the boots were perfect so I ended up only using the ball joint ends not the rod in the kit I purchased. I'm taking the rods to the steering guys tomorrow just incase they disagree :) - I'd say the rods you can see in the pic are the rear tow links. mine is that late 2007 sold in 2008 also according to the VIN.

I didn't use a special separator on the front main ball joint just a really big hammer :) but basically I took the lower arms and rotors off (just whipped the calipers of and tied them up.. to do it with a hammer, the bolt kits comes with new short shaft nuts for the font, you don't need to take the rear short shafts out. you have to take the short shaft out either way as to give clearance to remove the ball joint from the knuckle.

The only rubbers not done was in the rear knuckle... as I'm going to get 4 new knuckles and disc brake rotors this year sometime.. plus I didn't think this was an easy job to press out and they look ok for now. You will need dot 4 brake fluid but I was quick to disconnect/reconnect the brake lines in the rear so fluid loss and bleeding went quick and easy.

I 'serviced' my valve blocks last year when the air compressor changed to the new one as they were full of desiccant... but I decided to change them with this order and the suspension is quicker now and I feel better about it - and I have spares now.

According to the service manuals the rear roll bar was going to be... well really impossibility (at home, lifting the body) but this was to remove the bar and replace it not to just change rubbers so it was ok in the end with an offset 13mm spanner and ratchet spanner.




LR010670 (https://www.lrdirect.com/LR010670-supplied-by-britpart-branded-britpart.html)
KIT-STEERING GEAR TIE ROD REPA
AU$40.99
2
40.99


LR019117 (https://www.lrdirect.com/LR019117-supplied-by-britpart-branded-land-rover.html)
END-SPINDLE ROD CONNECTING
AU$151.34
2
302.68


RYH500116 (https://www.lrdirect.com/RYH500116-supplied-by-britpart-branded-land-rover.html)
NUT - ADJUSTING SCREW
AU$3.49
2
6.98


LR015339 (https://www.lrdirect.com/LR015339-supplied-by-BRITPART-branded-LR.html)
SPACER
AU$22.76
2
45.52


RBM500190 (https://www.lrdirect.com/RBM500190-supplied-by-BRITPART-branded-OEM.html)
LINK
AU$17.44
2
34.88


RGD000312 (https://www.lrdirect.com/RGD000312-supplied-by-BRITPART-branded-OEM.html)
JOINT
AU$26.16
2
52.32


DA7206 (https://www.lrdirect.com/DA7206-supplied-by-BRITPART-branded-BRITPART.html)
SUSPENSION ARM FITTING KIT D3/
AU$26.16
2
52.32


LR051592 (https://www.lrdirect.com/LR051592-supplied-by-BRITPART-branded-OEM.html)
ARM - REAR SUSPENSION
AU$113.38
1
113.38


LR051594 (https://www.lrdirect.com/LR051594-supplied-by-BRITPART-branded-OEM.html)
ARM - REAR SUSPENSION
AU$113.38
1
113.38


LR051622GK (https://www.lrdirect.com/LR051622GK-supplied-by-BRITPART-branded-ORIGINAL-EQUIPMENT.html)
ARM- REAR SUSPENSION KITUPPER
AU$142.61
1
142.61


LR051623GK (https://www.lrdirect.com/LR051623GK-supplied-by-BRITPART-branded-ORIGINAL-EQUIPMENT.html)
ARM - REAR SUSPENSION KIT UPPE
AU$142.61
1
142.61


RBJ500222GK (https://www.lrdirect.com/RBJ500222GK-supplied-by-BRITPART-branded-ORIGINAL-EQUIPMENT.html)
ARM - FRONT SUSPENSION KIT UPP
AU$86.95
1
86.95


RBJ500232GK (https://www.lrdirect.com/RBJ500232GK-supplied-by-BRITPART-branded-ORIGINAL-EQUIPMENT.html)
ARM - FRONT SUSPENSION KIT UPP
AU$86.95
1
86.95


LR075993GK (https://www.lrdirect.com/LR075993GK-supplied-by-BRITPART-branded-OEM.html)
ARM-FRONT SUSPENSION KIT RH
AU$193.11
1
193.11


LR015336 (https://www.lrdirect.com/LR015336-supplied-by-BRITPART-branded-OEM.html)
BUSH
AU$27.88
2
55.76


LR075995GK (https://www.lrdirect.com/LR075995GK-supplied-by-BRITPART-branded-OEM.html)
ARM-FRONT SUSPENSION KIT LH
AU$193.11
1
193.11










Total Suspension


1663.55









DA6041P (https://www.lrdirect.com/DA6041P-supplied-by-britpart-branded-oem.html)
SERVICE KIT - PREMIUM
AU$87.22
1
87.22


LR044836 (https://www.lrdirect.com/LR044836-supplied-by-BRITPART-branded-LR.html)
CONNECTOR - VALVE BLOCK TO PIP
AU$15.70
6
94.2


RVH000055 (https://www.lrdirect.com/RVH000055-supplied-by-britpart-branded-land-rover.html)
VALVE - LEVELLING
AU$196.17
1
196.17


RVH000095 (https://www.lrdirect.com/RVH000095-supplied-by-britpart-branded-land-rover.html)
VALVE - LEVELLING
AU$152.64
1
152.64


BHE780060 (https://www.lrdirect.com/BHE780060-supplied-by-britpart-branded-britpart.html)
LIFT ASSY
AU$17.43
2
34.86


LR009106 (https://www.lrdirect.com/LR009106-supplied-by-BRITPART-branded-OEM.html)
LIFT ASSY
AU$13.96
2
27.92


DA1114 (https://www.lrdirect.com/DA1114-supplied-by-BRITPART-branded-OEM.html)
FUEL LATCH REPAIR KIT
AU$13.09
1
13.09


LR085940 (https://www.lrdirect.com/LR085940-supplied-by-LAND-ROVER-branded-LAND-ROVER.html)
LATCH - TAILGATE
AU$66.40
1
66.4


LR085583 (https://www.lrdirect.com/LR085583-supplied-by-LAND-ROVER-branded-LAND-ROVER.html)
LATCH - TAILGATE
AU$66.40
1
66.4


RBU500100 (https://www.lrdirect.com/RBU500100-supplied-by-LAND-ROVER-branded-LAND-ROVER.html)
CLAMP - RUBBER BUSH
AU$4.39
2
8.78



Extra Items


747.68

[bjasch94]

Doing this kind of job might be a common DIY for most Aulro members but I for one am truly impressed that you did this I'm two and a half days at your home with no issues.

Are you a mechanic or have you just learnt the car over the decade you've had it?

I've had mime for 18 months now and couldn't dream of completing this job. Maybe there's hope for me though.
As an example, I was quoted $1400 to have my front LCAs replaced... I can see the value of being able to DIY.

Congratulations!

[DJL9999]

no issues.. hmmm well haven't had the 4 wheel alignment yet :) and then calibrated the suspension .... but no I'm just a guy with a D3 addicted to it and I've only had it for 2 years.. I originally brought it to drive around AUS then flog it off.... well then I fell in love with the bloody thing! I've only really worked on paddock bombs before this.

[specwarop]

Those arms arent the control arms right? I've read they cost $600+ to replace?

[DJL9999]

Yes they are control arms.. pretty cheap DIY especially 8 arms ... I was quoted 6-7k originally to do the lot.

I was just quoted $180 for a LRD to do 4 wheel alignment in Tight tolerance mode and on an approved machine so I’m going with that to make sure it’s done properly to LR specs (I’ll still be asking all the questions:)

[specwarop]

Hmm I wonder what the $600 control arms were, it seemed that was the cheapest when I was reading that thread...

[LRD414]

Hmm I wonder what the $600 control arms were, it seemed that was the cheapest when I was reading that thread...
That $600 may have been for a pair of genuine fronts including shipping.
I note that Don's part list in the post above includes links to the Britpart items on LRDirect.
I'm not sure what bushes are used in the Britpart ones.

Cheers,
Scott

PS .... well done to Don, that's a massive effort.

[PerthDisco]

Awesome effort. Wish there was a YouTube video or wiki in the making. I find that after the first few bolts you are fully committed. [emoji47]

[DJL9999]

Yes especially when you have the parts sitting looking at you :). There were a few real tough bolts to muscle and work at but it would have been a interesting YouTube with it bleeped out for most of it especially the rear passenger side..

[DJL9999]

My wheel alignment and suspension recalibration are sadly not going to happen until Monday 15th but I’m on a standby spot if there is a cancellation.

I’m going to leave the drawers and fridge in for the alignment...what does everybody think of that? It’s in the car more than it’s ever been out of it.... thinking of leaving the aux tank up half way full and a full tank in the main. Anyone have any objections?? Or thoughts?

[letherm]

My wheel alignment and suspension recalibration are sadly not going to happen until Monday 15th but I’m on a standby spot if there is a cancellation.

I’m going to leave the drawers and fridge in for the alignment...what does everybody think of that? It’s in the car more than it’s ever been out of it.... thinking of leaving the aux tank up half way full and a full tank in the main. Anyone have any objections?? Or thoughts?

My only thought would be a fuel economy hit with the extra weight.

Martin

[LRD414]

I’m going to leave the drawers and fridge in for the alignment...what does everybody think of that? It’s in the car more than it’s ever been out of it.... thinking of leaving the aux tank up half way full and a full tank in the main. Anyone have any objections?? Or thoughts?
Wont make any difference. The suspension self-levels to correct height regardless of load on board. When in TTM it simply self-levels more accurately to the correct height.

Scott

[DJL9999]

My only thought would be a fuel economy hit with the extra weight.

Martin

Cheers yeah not high on the priority that one with all the crap I have hanging off it or in it I sit on about 12lt/100 and 15lt/100 with camp trailer down to 9 when the roof rack and other crap is out :)- any excuse to be able to go hunting/fishing or camping at the drop of a hat :)

[Russrobe]

Cheers yeah not high on the priority that one with all the crap I have hanging off it or in it I sit on about 12lt/100 and 15lt/100 with camp trailer down to 9 when the roof rack and other crap is out :)- any excuse to be able to go hunting/fishing or camping at the drop of a hat :)All this in 2 days is good effort for a home garage. Did you have a compressor and rattle gun? I found that made short work of the lower arm bolts. Not sure it would be much help up top with no room.

Going to try all 4 wheel bearings and CV joints next? [emoji16]

[DJL9999]

Did my CV joints on a beach some time ago hahah. Heavy trailer and a real close call with the tide :).

Yep rattle gun all the way.. been the Best Buy ever especially for changing from the road to mud tyres.

Drove down to Sydney this week and started to have a HDC faults show up a fair few times in the last hour of the trip so I left it in Gosford for now - so I have to deal with that tomorrow... hmmm doubt it is a battery issue as I only just replaced it a couple of months ago... pretty nervous hopefully because I left it in Gosford someone stole it... not that they will have got far.. hahah.

[JonW]

Awesome effort for two and a bit days. Holy cow, just did my lower fronts on my 2010 D4 for the second time at 220k kms.

Besides needing a wheel alignment it now comes up with two errors - Stability Control not available, Emergency Brake assist not available.
Had a quick look, no cables dislodged or broken, any ideas?

[Disco-tastic]

Did my CV joints on a beach some time ago hahah. Heavy trailer and a real close call with the tide :).

Yep rattle gun all the way.. been the Best Buy ever especially for changing from the road to mud tyres.

Drove down to Sydney this week and started to have a HDC faults show up a fair few times in the last hour of the trip so I left it in Gosford for now - so I have to deal with that tomorrow... hmmm doubt it is a battery issue as I only just replaced it a couple of months ago... pretty nervous hopefully because I left it in Gosford someone stole it... not that they will have got far.. hahah.I had faults show up just after changing my lower arms. Not sure why but my guess is that the height sensors got moved around a bit. I also had traction control activation on dry bitumen roads after changing the front hubs. Maybe I tickled the abs sensor the wrong way?

Both issues disappeared within a tank of fuel, with a hard reset clearing them I believe.

PS. Good effort on the suspension. Having changed the front LCA bushes in my driveway in pretty keen to get a hoist prior to more suspension work!

[DJL9999]

Awesome effort for two and a bit days. Holy cow, just did my lower fronts on my 2010 D4 for the second time at 220k kms.

Besides needing a wheel alignment it now comes up with two errors - Stability Control not available, Emergency Brake assist not available.
Had a quick look, no cables dislodged or broken, any ideas?

Mate sounds like the traction control lead/s have been damaged or not seated properly after dismantle? its the lead that has a bolt holding the end of the lead in (magnet) on what looks like a sprocket on the hub/bearing housing which is the accelerometer on each of the 4 wheels.

[JonW]

Thanks DJL9999, the stub axles did not part from the hubs but they did get pushed around a bit. I will start checking there.

Thanks again

[Highcam]

Hi DiscoJeffster - I ordered a mix of parts but the arms are OEM - all parts LRD Workshop approved 2 Year warranty (my thought process was it must be a good part) also some LR parts where the price wasn't too far away! everything looks great from initial inspection and the last of the boxes rocked up.. so I have everything now. I did the compressor last year and it has been going strong, doing the valve blocks this round. actually the only parts I haven't done yet are the airbags..


Hey dude, if you are considering airbag replacement check out Arnott Industries in the US. I got 4 airbags for my 94 LSE from them for the same price as one genuine airbag!! Still working great after several years!!!!
Cheers. Mike

[pastor098]

Haven't read yet, how is the ride after the suspension overhaul?!

[JonW]

After a wheel alignment both warnings have disappeared and the front end does not sag to access when the engine stops.

Not sure of the Landrover logic but I am not arguing haha

[DJL9999]

Haven't read yet, how is the ride after the suspension overhaul?!

worth every cent, drop of blood, sweat and tears...

[SeanC]

Hi Don,
l’m getting more hands on with my 2008 D3. Might leave a job the size of yours for a bit.
I’ve been putting together a set of tools and am wondering if you are using torque wrenches?

You see YouTube vids from places like Atlantic British with not a torque wrench in sight.

[DJL9999]

Hi Don,
l’m getting more hands on with my 2008 D3. Might leave a job the size of yours for a bit.
I’ve been putting together a set of tools and am wondering if you are using torque wrenches?

You see YouTube vids from places like Atlantic British with not a torque wrench in sight.

Yeah so... I have two of them and I was as keen as you with them until I figured out they just don’t fit anywhere in and around the car!

On the bolts that I can get onto I usually have a play to see what various toques feel like but basically if I had to use a pipe and a hammer to get it undone I usually use the equal force to do it back up! Haha.