Discovery (1995+): Body Repair Manual - part 18

CHASSIS AND BODY

REPAIR

ADJUSTMENT-REAR SIDE DOOR LOCK AND
HANDLE

Service repair no - 76.37.47

Outside door release handle to lock

1. Disconnect the short off-set connecting rod at

the rear of the outer release handle, rotate the
rod clockwise or counter clockwise to shorten or
extend the operating length of the rod as
required.

NOTE: Door release should occur before
the total handle movement is achieved to
provide a small overthrow movement.

REAR SIDE DOOR GLASS AND REGULATOR

Service repair no - 76.31.45

Remove

1. Ensure that the window is in the fully closed

position and secure it with adhesive tape over
the top of the door to prevent the glass from
dropping down.

2. Disconnect battery negative lead.
3. Remove the door trim panel.

See this section.

4. Remove the plastic vapour barrier.
5. Where applicable remove the door actuator and

window lift motor.

See ELECTRICAL, Repair.

6. Remove the four window regulator securing

screws and shakeproof washers from the inner
door panel.

7. Carefully disengage the lifting arm stud from the

glass lifting channel and remove the window
regulator from the lower opening in the inner
door panel.

8. Remove the waist rail seal from the top of the

door panel.

9. Remove the single bolt, spring and plain

washers from inside the door, securing the
bottom of the short glass run channel.

10. Remove the two bolts, spring and plain washers

from the hinge face of the door.

CHASSIS AND BODY

REPAIR

11. Remove the two bolts, spring and plain washers

securing the door frame to the edge of the door.

12. Lift out the door frame complete with glass and

remove to a suitable workbench.

13. Remove the tape and slide the glass out of the

door frame channel.

Refit

14. Reverse removal procedure.

NOTE: When refitting the door glass frame
ensure that it is adjusted to suit the door
opening before fully tightening the

securing bolts.

REAR DOOR

Service repair no - 76.28.19

Remove

1. Remove the spare wheel from the exterior of the

door.

2. Remove the trim panel from inside the rear door.

See this section.

3. Release the convoluted grommet from the door

post, expose the door harness connectors and
multiplugs and disconnect.

4. Remove the circlip and washer from the check

stay pivot on the body.

WARNING: Instruction 5 MUST BE carried
out with assistance.

5. Suitably support the door, remove the four bolts

securing the hinges to the door and with
assistance slide the door off the hinges.

Refit

6. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

REAR DOOR TRIM PANEL

Service repair no - 76.34.09

Remove

1. Remove the two screws securing the door pull

and remove it from the door.

2. Remove the finisher from the inner door handle.
3. Using a trim panel removing tool release the

seventeen trim panel fasteners and withdraw the
panel from the door.

4. If necessary remove the sixteen screws securing

the stowage bins to the trim panel and detach
the bins.

Refit

5. Reverse removal procedure.

REAR DOOR LOCK AND INNER AND OUTER
RELEASE HANDLES

Service repair no - 76.37.16/74/77/78

Remove

1. Disconnect battery negative lead.
2. Remove the door pull, the trim panel and the

vapour protective sheet, to allow access to the
door handles and lock mechanisms.

3. Disconnect the inner release handle connecting

rod at the lock.

4. Remove the two screws securing the inner

handle and withdraw the handle complete with
connecting rod.

NOTE: Two identical ’Y’ shaped levers
(bellcranks) are fitted to the rear door lock
mechanism and are referred to as inner

and outer ’Y’ levers; the inner one being the
nearest to the inner door panel.

5. If fitted, remove the central locking actuator

control rod link from the actuator and from the
inner ’Y’ lever.

6. Detach the remote button connecting rod at the

inner ’Y’ lever and withdraw from inside the door.

7. Detach the lock and barrel connecting rods from

the upper leg of the inner ’Y’ lever.

CHASSIS AND BODY

REPAIR

8. Remove the screws securing the lock control

mechanism pivot bracket and the door pull
mounting bracket, ease the bracket from the lock
barrel stem and remove from the door.

9. Remove the two screws and withdraw the

childproof lock actuator.

10. Disconnect the adjustable lock rod from the

outer ’Y’ lever.

11. Remove the centre pin from the outer ’Y’ lever

pivot and release the pivot from the door.

12. Remove the three lock securing screws and

manoeuvre the lock and ’Y’ lever out of the door
panels.

13. Disconnect the number plate light leads from the

door harness.

14. Remove the ’E’ clip securing the fulcrum to the

barrel stem and withdraw the fulcrum and lock
rod.

15. From inside the door panel remove the nuts and

washers securing the lock barrel and number
plate light housing.

16. Remove the logo from the housing and working

through the logo aperture, remove the single bolt
securing the housing.

17. Partially withdraw the housing and its rubber

seal from the door, displace the rubber grommet
from the door panel, withdraw the number plate
light leads and complete the removal of the
housing and seal from the door.

18. Remove the connecting rod from the outer door

handle lever.

19. Remove the two nuts and washers securing the

outer handle from inside the door panels and
detach the handle and seal.

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