Weak Link: Radiator Hoses
Models Affected: '99-'04 Discovery II
What Happens: Over time, the heater hoses may leak due to insufficiently tightened clamps, causing coolant to puddle on the intake manifold. In addition to making a smelly mess, this can also result in low coolant levels that can lead to larger problems.
Sturdy Fix: The easiest fix is to simply tighten the existing fasteners, but replacing the hose clamps with fuel-injection clamps will improve reliability.
Contact: Your local parts store
Weak Link: Park MechanismModels Affected: '95-'99 Discovery I
What Happens: Controls on the Discovery prohibit the transmission from being shifted out of Park if the brake system is not functioning properly. While this is useful in preventing accidents, unfortunately the controls fail at a higher rate than the brake system.
Sturdy Fix 1: The first step is to see if your brake lights are functioning. If not, check the F1 fuse to see if it is blown. Also check the brake-light terminals to ensure that they are not touching and causing a short.
Sturdy Fix 2: If the fuse is intact, the brake switch is the likely culprit. This switch activates your brake lights as well as the shift interlock solenoid that permits your shifter to move from Park when the brake pedal is depressed. While there is no aftermarket upgrade available, factory replacements are available from Expedition Exchange for less than $35. It is recommended you carry a spare brake switch since they are small, inexpensive, and easy to swap out if necessary.
Contact: Expedition Exchange
Weak Link: Rear Suspension Geometry
Models Affected: '94-'99 Discovery I
What Happens: As the rear suspension is lifted with taller coils and longer shocks, the geometry changes. The suspension links are effectively shortened as they become more angled, moving the axle forward in relation to the frame.
Sturdy Fix: Rovertym manufacturers custom A-arm extensions to each user's specifications depending on their suspension setup. The extension bolts to the A-arm and relocates the existing rear swivel link to the rear up to 1 inch. Also, for 3-inch-or-more lifted trucks, this link will restore some of the lost rear A-arm swivel joint geometry, which diminishes as the suspension is lifted.
Contact: Rovertym
Weak Link: IAC Stepper Motor
Models Affected: '94-'99 Discovery I
What Happens: Over time, you may notice a hesitation and rough idle from your engine. The engine may even stall when under a load from the power steering or air conditioning. The problem is that the idle air-control motor is subjected to high amounts of heat and debris that can contaminate it over time. This motor compensates for engine loads at idle by regulating the air that bypassed the throttle plate when it is closed.
Sturdy Fix: The idle air-control motor is a small round motor with an electrical connector on the top, located on the upper air plenum. To service it, you'll have to remove the motor from the plenum and clean the end of the valve. You should also clean the passage that it fits into with carb cleaner. If the symptoms remain after cleaning, the motor more than likely needs to be replaced.
Contact: None
Weak Link: Steering Rods
Models Affected: '99-'04 Discovery II
What Happens: The stock tie rod and drag link are constructed out of wimpy 0.80-inch tubing with a 0.10-inch wall thickness. They suffer a severe allergic reaction to rocks and tall tires by bending themselves into all kinds of inconvenient shapes.
Sturdy Fix: Steering links constructed from 1.25-inch tubing with almost double the wall thickness are available from Rover Tracks. The new steering links are also threaded for tie-rod ends at both ends, unlike the stock tie rod, which has crimped ends and is not reusable with new tie-rod ends. Additionally, a high-clearance tie rod is available for even greater protection against bending and breakage.
Contact: Rover Tracks
Weak Link: Rear Coil Springs
Models Affected: All
What Happens: The rear four-link suspension design used on Rovers is a superb design. After adding longer shocks and brake lines, the articulation becomes so plentiful that the coil spring unseats.
Sturdy Fix: Spring retainers or "cones" are available from Rovertym to cure this problem. These simple bolt-on products guide the coil back into the spring retainer and keep them from unseating.
Contact: Rovertym