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 
suitable  piece 
of timber  between  the appropriate 
piston  and caliper. 
7. Finally,  remove the pistons  keeping  them 
identified  with their  respective  bores. 
8. Remove the wiper seal retainer  by inserting a  blunt 
screw  driver between  the retainer  and the seal and 
prise  the  retainer  carefully from  the  mouth 
of the 
bore. 
9. Taking care  not to damage  the seal  grooves, extract * the wiper seal  and fluid seal. 
10. Clean  the  bores,  pistons  and  particularly the seal 
grooves  with clean  brake  fluid or methylated  spirit 
only.  If the  caliper 
or pistons  are corroded  or if 
their condition  is not perfect the parts  must be 
renewed. 
1 
70 
/- 
Assemble  rim-half pistons 
11. Coat a new  fluid  seal with  Lockheed  disc brake 
lubricant.  Ease the seal  into the groove  in the  bore 
using  only  the fingers  and ensure  that it 
is properly 
seated.  The fluid  seal  and  the groove  are not  the 
same 
in section so that  when  the seal  is seated  it 
feels  proud  to the  touch at the edge  furthest away 
from 
the mouth  of the bore. 
. I* 
12. Smear  the  appropriate  piston with  disc  brake 
lubricant  and  insert  it squarely  into  the  bore  by 
hand  only. 
Do not tilt the  piston  during insertion 
and  leave  approximately 
8 mm projecting  from the 
bore. 
13. Coat  a new  wiper  seal with  disc  brake lubricant  and 
fit it to a new  seal retainer.  Slide the assembly,  seal 
first,  over the protruding  piston and into  the bore 
recess.  Remove  the piston  clamp 
from the 
mounting  half and use 
the clamp to prcss home the 
seal  retainer  and piston. 
Mounting
-half  pistons 
14. Clamp  the rim-half  pistons  and carry  out the same 
procedure  as for  removing  and fitting  the rim  half 
pistons  and seals,  instructions 
6 to 13. 
Fit calipers and pads to vehicle 
15. Fit the caliper  to the  axle  and secure  with the two 
bolts  tightening  evenly 
to the correct torque, sce 
data. 
16. Connect the brake  flcxiblc  hose to the calipcr and 
remove the  hose clamp. 
17. Lightly  smear the  back and edges of the  pads with 
disc  brake  lubricant  carefully  avoiding  the friction 
material. 
18. Fit the  friction  pads and  secure  using ncw pins and 
rctaining clips or split  pins  (latest  type)  and  anti- 
rattle  springs.  Splay  the cnds of thc early typc 
retaining pins. 
19. When  the  foregoing  instructions  have been 
completed on both  calipers,  depress  the  brake 
pedal  firmly  several  times to locate  the  friction 
pads. 
20. Fit  the  road  wheels, rcmovc the  axle  stands  and 
finally  tighten  the road  wheel nuts, see data. 
21. Road  test the vehicle,  remembering  that if new 
friction  pads have  been fitted  they are 
not ‘bedded- 
in’ and  may  take  several  hundred  miles before  the 
brakes  are at maximum  efficiency. 
5  
						

							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 
the brake  drum. 
4. Remove  the trailing  shoe anchor  plate. 
5. Lever off the brake shoes  whilst noting  the position 
of  the  pull
-off springs. 
6.  Disconnect  the  brake fluid  pipe  to the  wheel 
cylinder and  cover the pipe 
end to prevent  ingress 
of  dirt. 
ST745M 4 
7. Remove  the  two  retaining  nuts  and withdraw  the 
wheel  cylinder from  the back
-plate. 
Dismantle and overhaul wheel cylinder 
8. Remove  the two dust covers. 9. yqithdra.w tiie pistoiis arid discard 
10. Remove  the spring. 
11. Remove the bleed  screw. 
12. Clean  components  with Girling  cleaning  fluid  and 
allow  to dry. 
13.  Examine  the  cylinder and pistons  for corrosion, 
scores and wear.  Renew any component that  is not 
satisfactory  or replace  complete  cylinder assembly. 
6 
14. Fit new seals  to the  pistons noting  that the seal lip is 
15. Lubricate the  pistons with  new clean  Girling  brake 
16.  Fit the  spring between  the two  pistons. 
17. Fit the  dust  covers. 
18. Fit a  rubber  band around the  cylinder to  retain  the 
19. Fit the  bleed  screw  and tighten  to 0,5 to 0,8 kgf m 
towards the 
cylinder. 
fluid. 
parts,  until the brake  shoes are 
in position. 
(4 to 6 Ibf  ft). 
ASSEMBLING REAR BRAKE 
1. Fit  the  wheel  cylinder  to the back-plate and  secure 
with  the two nuts and spring  washers. 
2. Reconnect the pull-off spring  to the  brake  shoes 
and  fit the  shoes at  the wheel  cylinder  end first. 
3.  Reconnect  the leading shoe pull
-off spring; replace 
it  with  its  long  end  hooked  over  the post on the 
shoe  web. 
4. Refit  the trailing  shoe anchor  plate and secure  with 
the  two  bolts  and tab plate. 
5. Turn  the adjuster on the  back-plate to check 
operation. 
6  Connect  the brake  fluid pipe 
to the wheel  cylinder. 
7. Examine  the  brake  drum  for internal  scoring and 
ovality.  If required,  the interior 
of the drum  can be 
machined  to a  maximum  diameter 
of 255,52 mm 
(10.060 in). 
8. Fit the  brake  drum and  ensure  that it seats 
correctly  on the  hub  register  and secure  with the 
single  screw. 
9. Turn the adjuster  on the back-plate until the brake 
shoe 
is locked  against  the drum.  Back off 
approximateiy  two  serrations 
so [hat the drum 
revolves freely. 
10. Repeat the procedure for  the opposite brake. 
11.  Bleed  the brakes. 
12. Fit the  road  wheels,  remove  the axle stands  and 
finally  tighten  the road  wheel  nuts to the  correct 
torque.  
						

							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 brake  drum. 
3. Disconnect  the  brake fluid pipe to the  wheel 
cylinder  and cover  the pipe  end to  prevent  ingress 
of  dirt. 
4. Remove  the two  retaining  nuts  and withdraw  the 
wheel cylinder  from the back
-plate. 
ST 
Dismantle and overhaul wheel cylinder 
7. Remove the  two dust  covers. 
8.  Withdraw  the pistons  and discard  seals. 
9. 
Removc the  spring. 
10. Remove  the bleed  screw. 
11. Clean  components  with Girling  cleaning  fluid and 
allow  to dry. 
12. Examine  the cylinder  and pistons  for  corrosion, 
scores and  wear. Renew  any component that  is 
not 
satisfactory or replace  complete  cylinder assembly. 
13. Fit new  seals to the pistons noting that  the seal  lip is 
towards the  cylinder. 
14. Lubricate the pistons  with new clean  Girling  brake 
fluid. 
15. Fit the  spring between  the two  pistons. 
16. Fit the  dust  covers. 
17. Fit the  bleed  screw  and  tighten to 0,5 to 0,8  kgf m 
(4 to 6 Ibf ft). 
7 
ST619M 
Assembling  rear brake 
18. Fit the  wheel  cylinder to the back-plate  and secure 
19. Assemble new brake shoe pull-off  springs to re- 
with  the two  nuts and  spring washers. 
lined  brake shoes as illustrated. 5. Remove  the single  retaining Screw and withdraw 
6. Lever off the brake  shoes whilst  noting  the position 
the brake drum. 
of 
the pull-off  springs.  continued 
5 ST 1 
STl165M 7  
						

							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  cam so that the drum  revolves freely. 
25. Repeat instruction  24 on  the  second  shoe and carry 
out  the same  procedure  for the  opposite  brake. 
26. Bleed the brakes. 
27. Fit  the  road  wheels,  remove  the  axle stands and 
finally  tighten  the road  wheel  nuts  to the  correct 
torque. 
OVERHAUL  TRANSMISSION  BRAKE 
WARNING:  Do not  use an air  line to  remove  dust from 
the  brake  assembly.  Asbestos dust  from  the brake 
linings  can be a serious  health risk, 
if inhaled. 
DISMANTLING 
1. 
2.  Disconnect the propeller  shaft  from  the  output 
flange. 
3. Remove  the  two  screws  and withdraw  the  brake 
drum.  Skim 
if excessively  scored or oval. 
4. Remove the  split pin and clevis pin  connecting  the 
drawlink  to the actuating  lever. 
5. Remove the brake  shoes  complete  with pull-off 
springs.  Note position 
of springs  in relation  to the 
shoes. 
6. Remove  the four  bolts  securing  back-plate to 
transfer  box and withdraw  the back-plate  complete 
with 
oil catcher. 
KEY  TO TRANSMISSION BRAKE 
1. Brakedrum. 
2. Brake  drum retaining screws. 
3. Brake shoes. 
4.  Brake  shoes pull
-off springs. 
5. Expander  assembly. 
6. Adjuster assembly. 
7. Drawlink. 
8. Oil catcher. 
9. Back plate and retaining bolts. 
10. Dust cover. 
11. Locking plate. 
12. Packing plate. 
13. Spring  plate. 
9 
ST1192M ‘2 
8  
						

							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 assembly 
14. Grease  and fit the expander  and drawlink. 
15. Grease and fit the  plungers  and  rollers noting  that 
the  highest  end 
of the ramp  on the  plungers  is fitted 
towards  the back
-plate.  Secure  the assembly with  a 
rubber  band to prevent the  plungers falling out and 
place 
to one  side for assembly  to back-plate. - 
-127% 
Remove  and overhaul  adjuster assembly 
16. Remove  the two  bolts  and withdraw  the  adjuster 
17.  Remove the  plungers. 
18. Screw the adjuster cone inwards  to remove  from 
19. Clean the  parts in Girling  cleaning  fluid and discard 
assembly 
from the back
-plate. 
the housing. 
any unsatisfactory  components. 
Assemble adjuster assembly 
20. Grease  and screw  in the adjuster  cone. 
21.  Grease and  fit the adjuster  plungers  and  align the 
chamfered  ends with the adjuster cone.  Note that 
the  two  plungers  are identical  and  can be fitted 
to 
either  bore.  Secure  the assembly  with a  rubber 
band 
to prevent  the plungers  falling out. 
ASSEMBLE 
NOTE: 
If the  brake  linings  are oil-soaked  check and if 
necessary  renew the output  shaft oil seal. 
22.  Position  the expander  assembly on the  inside  of the 
back
-plate  and  secure with the following  plates at 
the rear 
of the  back-plate. 
23.  Packing piece. 
24. Locking plate. 
25.  Retainer  spring. 
26. 
Fit the  rubber  dust cover. 
continued 
 :..::d. . . .. , .. . ... . , .. . , > ,. ,., ...,. . .. 
9  
						

							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  the adjuster  assembly. 
29 
ST1275M 
30. Fit the brake drum  and secure with the two  screws. 
31.  Connect  the expander  drawlink to the  actuating 
lever  with a new clevis  pin, washer  and split pin. 
32.  Turn 
the adjuster cone  fully in and tighten  the two 
retaining  bolts 
left slack in instruction  27. 
33.  Slacken  off 
the adjuster  two ‘clicks’  and firmly 
apply  the  hand lever  to centralise  the  shoes. The 
drum  should 
then rotate  freely. 
34. Adjust  the  handbrake  cable to give the pawl  two 
‘clicks’  free movement 
on the  ratchet  before  the 
third  ‘click’  fully expands  the  shoes  against the 
drum. 
35.  Connect  the propeller  shaft and  evenly tighten the 
retaining 
nuts to the correct torque. 
36. Remove  chocks  from  wheels  and  connect the 
battery. 
BLEEDING THE BRAKES 
Primed System 
Bleed  the front  brakes  first starting  with the wheel 
nearest  to the master  cylinder. 
1. Attach a rubber  tube  to the  bleed  screw  and 
immerse  the  other end 
in a glass jar containing a 
quantity  of clean,  new recommended  brake fluid. 
2.  Check that the  fluid reservoir  is full 
to the maximum 
mark. 
3. Unscrew the bleed  screw approximately  half-a-turn, 
enough  to allow  fluid 
to be  pumped  out. Do not 
open the screw  too far or air  will  be drawn  back into 
the  system  around  the threads. 
4. Smartly  depress  the  foot pedal,  pause and then 
allow  the pedal  to rapidly  return, pause again before 
repeating  the procedure. 
5. Continue  with the above  sequence  until all air 
bubbles  cease whilst  ensuring  that the reservoir  is 
kept  topped
-up. 
6.  Close  the bleed  screw  immediately  after  the last 
down  stroke,  whilst 
the pedal is depressed. 
Unprimed System 
To bleed  a  replacement  master  cylinder or a fully 
drained  system. 
7.  Top  up the 
fluid reservoir  to the  maximum  mark. 
8. Open a bleed  screw in both  circuits  and allow  fluid 
to  prime  both  circuits 
of the mastcr cylinder by 
gravity  for  approximately  five minutes,  then  bleed 
as  for a primed system. 
10  
						

							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  two 
surplus 
fluid. 
rubber  seal. 
reservoir  from  the master  cylinder. 
reservoir retaining seals. 
KEY  TO MASTER CYLINDER 
1. Reservoir. 
2. Reservoir  filler cap. 
-3. Rubber  seal. 
4. Plastic baffle. 
5. Roll pins. 
6. Reservoir retaining  seals. 
7. Secondary plunger stop pin. 
8. Plastic  circlip 
9. Primary plunger assembly. 
10. Secondary plunger assembly. 
11. Master  cylinder  flange seal. 
12. Nuts and washers securing  cylinder to servo. 
STllS4M 
.. . . ..., 
						

							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  the 
method  illustrated  for 
rencwing the secondary scals 
following  instruction 16. 
13. Fit the recuperating  seal assembly  parts in the 
reverse  order of removal.  Compress the  spring and 
secure  the assembly  with the bolt  tightening  to 2 to 
3 Nm (1.5  to 2.2  Ibf ft). Do not  overtighten. 
continued 
f-8 .... +.&* 
13 a! 12 
Renewing primary plunger seals 
10.  Using  a 2.5 mm Allen key, unscrew  the retaining hAlt F,,, th- -,;-,,., -I,.-*-- ,-A -n-,.IY. UULL LIUIII LILL piiiiiaiy piuiifjb~ aiiu ILIIIUVL. 
(a) spring  retainer ST1197M 
(b) plunger spring 
(c) seal  retainer 
(d) recuperating  seal 
(e)  washer 
the  outer  seal. 
11. Taking  care not to  damage  the  plunger, prise off 
12