Land Rover Defender 90 110 Workshop Book 4 Rover

BRAKING SYSTEM 170 I 
KEY TO CALIPER 
1. Bleed screw. 
2. Caliper. 
3. Anti-rattle springs. 
4. Retaining  pins. 
5. Friction pads. 
6. Brake disc. 
7. Piston. 
8. Wiper seal retainer 
9. Wiper seal. 
?. *, .? , * 
10. Fluid seal. 
FRONT BRAKE  CALIPER  ASSEMBLY  (EARLY TYPE) 
3 
ST1271M 1 
3  

BRAKING SYSTEM 
FRONT BRAKE CALIPER ASSEMBLY (LATER TYPE) 
. 
8 
KEY TO CALIPER 
1. Bleed screw. 
2. Caliper. 
4. Retaining pins and clips. 
5. Friction pads. 
6. Brake disc. 
7. Piston. 
8. Wiper  seal retainer. 
9. Wiper  seal. 
3. Anti-rattle springs; 
10. Fluid seal. 
4 
I 
ST1809M  

BRAKING SYSTEM 
DISMANTLE AND OVERHAUL 
Do not separate the caliper  halves. 
r: . . .I sr. 
5. Clean the outer  surfaces  of the  caliper  with 
methylated  spirit. 
6. Using special  tool 18G672, clamp the pistons  in the 
mounting  half 
of the  caliper  and gently,  keeping 
fingers  clear, and with  CAUTION,  apply air 
pressure 
to the  fluid  inlet port  to expel  the rim  half 
pistons.  Since  it  is unlikely  that  both  pistons will 
expel  at the  same  time,  regulate the rate  with  a...

1701 BRAKING SYSTEM 
OVERHAUL REAR BRAKES - 90 models 
DISMANTLING 
WARNING: 
Do not use  an air  line  to blow dust  from the 
brake  assemblies 
- asbestos  dust from  brake  linings 
can 
be a serious  health risk  if inhaled. 
1. Slacken  the  road wheel  nuts, jack-up the  vehicle, 
lower  onto axle stands  and  remove  the road 
wheels. 
2. Slacken the brake  shoe adjuster  on the rear  of the 
back
-plate  to  assist removal  of brake  drum. 
3. Remove  the single  retaining  screw and withdraw...

BRAKING SYSTEM 
i I .,.. yr.:::  --r ..I OVERHAUL REAR BRAKES - 110 models 
DISMANTLING 
WARNING: Do 
not use  an air  line to  blow dust from the 
brake  assemblies 
- asbestos  dust  from  brake  linings 
can  be a serious health risk  if inhaled. 
:.:::f!,. , ... iy .,> ..., .. . . 
1. Slacken  the road  wheel  nuts,  jack-up the  vehicle, 
lower  onto axle stands  and  remove  the  road 
wheels. 
2. Slacken  the two  brake shoe adjusters  on the  rear  of 
the  back
-plate to assist  removal  of...

1701 BRAKING SYSTEM 
20. 
21.  Locate  the 
shoes in the  wheel  cylinder  piston  slots 
and  lever  the opposite  ends into the  pivot block. 
Operatc the snail cams  to check  that the shoes 
respond. 
22. Connect the brake  fluid pipe to the  wheel  cylinder. 
23. Fit the  brake  drum  and  secure with the single 
screw. 
24. Adjust  each brake  shoe independently  as follows: 
turn  one adjuster  until the shoe  is locked  against 
the  drum.  Back off approximately two  serrations 
of 
the snail...

BRAKING SYSTEM 170 
Remove and overhaul  expander  assembly 
7. Remove  the rubber  dust cover. 
8. Remove the  expander and draw link. 
9. Remove  the retainer  spring plate. 
10.  Remove  the locking  plate. 
11.  Remove  the packing  plate  and  withdraw the 
12.  Remove the two  plungers and rollers. 
13. Clean all parts  in Girling  cleaning  fluid and allow  to 
dry.  Examine  the components  for wear and  discard 
if unsatisfactory. 
expander 
assembly from the back
-plate. 
Assemble  expander...

1701 BRAKING SYSTEM 
27. Fit the adjuster  assembly to the back-plate  with the 
two  bolts but  do not  fully  tighten  at this  stage. 
28. 
Fit the  back-plate  assembly  and mud  shield  to the 
transfer  box with  the four  bolts  and tighten  to the 
correct torque. 
29. Fit  new  pull-off springs  to relined  brake shoes and 
fit to the  back-plate.  Note that the fully  lined  end 
of the lower shoe must  be  toward  the  expander 
assembly  and  the fully lined  end 
of the upper  shoe 
towards...

BRAKING SYSTEM 
6. Secure the master  cylinder in a vice  and push the 
primary  plunger  down  the  bore and withdraw  the 
secondary  plunger stop pin. 
- , I” . _-_ OVERHAUL  THE MASTER  CYLINDER ._ I,, 
1. Remove  the  master  cylinder from the servo  and 
vehicle. 
70 
continued 2. Remove  the master  cylinder  filler cap and pour off 
3. From  the  filler cap, prise  out the plastic  baffle  and 
4. Drive out  the  two roll  pins  and  remove  the 
5. Prise  out  from  the master  cylinder  the...

BRAKING SYSTEM 
7. Press  down the primary  plunger  and  remove  the 
8. Withdraw the primary  plunger assembly. 
plastic 
circlip. a I 
. 
I 
11 b c 
11 I 
9. Tap the  master  cylinder sharply on  a soft or ST1195M 
wooden  surface  to remove  the  secondary  plunger 
assembly. 
12. Fit a  new  outer  seal into  its groove  by squeezing the 
seal  between  the finger and  thumb into an  ellipse 
and  press the  raised part of the  seal  over  the flange 
using  the fingers 
of the other  hand.  Using...