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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
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70BRAKES 2 REPAIR SENSOR - ABS - FRONT WHEEL Service repair no - 70.65.30 Remove 1.Raise vehicle on a 2 post ramp. 2.Carefully prize ABS sensor from front hub. 3.Release clip securing ABS sensor harness to brake pipe. 4.Release clip securing ABS sensor harness to inner wing. 5.Lower vehicle. 6.Release second clip securing ABS harness to inner wing. 7.Disconnect sensor harness multiplug. 8.Remove sensor and harness. Refit 9.Connect sensor harness multiplug. 10.Position sensor harness and secure to inner wing with clip. 11.Raise vehicle. 12.Secure harness to inner wing and brake pipe with clips. 13.Apply grease to sensor. 14.Carefully fit sensor to hub assembly. 15.Lower vehicle.
BRAKES 3 REPAIR SENSORS - ABS - REAR WHEELS Service repair no - 70.65.31 Remove 1.Raise vehicle on a 2 post ramp. 2.Remove both rear wheels. 3.Remove 3 bolts securing each brake disc backplate to hub assemblies. 4.Remove both back plates. 5.Remove 2 cable ties securing sensor harness to outer ends of axle. 6.Carefully prise both sensors from hub assemblies. 7.Release 4 clips securing sensor harness to axle. 8.Release cable tie securing harness to differential. 9.Release 3 cable ties securing harness to chassis longitudinal. 10.Disconnect sensor multiplug. 11.Remove harness and sensor assembly. Refit 12.Position harness and sensor assembly to vehicle and connect multiplug. 13.Apply grease to both sensors. 14.Carefully fit both sensors to hub assemblies. 15.Secure harness to axle and differential with cable ties. 16.Secure harness to axle with clips. 17.Secure harness to chassis with cable ties. 18.Fit both back plates to hub assemblies and secure with bolts. 19.Fit rear wheels and tighten to130 Nm (95 lbf.ft) . 20.Lower vehicle.
70BRAKES 4 REPAIR MASTER CYLINDER Service repair no - 70.30.08 Remove 1.Disconnect battery negative lead. 2.Place a container under the master cylinder to collect any brake fluid spillage. CAUTION: Do not allow brake fluid to contact paint finished surfaces as paint may be damaged. If spilled, remove fluid and clean area with clean warm water. 3.Clean area around master cylinder ports. 4.Loosen 2 unions securing brake pipes to master cylinder ports. 5.Disconnect both brake pipes from master cylinder. Cover, not plug, pipe ends to prevent entry of dirt. 6.Disconnect 2 Lucars from reservoir cap. 7.Remove 2 nuts securing master cylinder to brake servo. 8.Withdraw master cylinder from servo and remove. Do not carry out further dismantling if component is removed for access only.9.Carefully ease reservoir from master cylinder by rolling it from seals. 10.Remove seals from master cylinder. NOTE: Master cylinder to reservoir seals are different sizes. 11.Fit NEW seals to master cylinder, ensuring seals are fitted to correct ports. 12.Fit reservoir to master cylinder. Refit 13.Ensuring that water ingress seal is in position, fit master cylinder to servo. 14.Fit nuts securing master cylinder to servo and tighten to26 Nm (19 lbf.ft). 15.Connect brake pipes to master cylinder and tighten unions to15 Nm (11 lbf.ft). 16.Connect Lucars to reservoir cap. 17.Fill reservoir with recommended brake fluid.See LUBRICANTS, FLUIDS AND CAPACITIES, Information. 18.Bleed the brake system.See Adjustment. 19.Reconnect battery negative lead.
BRAKES 5 REPAIR SERVO ASSEMBLY Service repair no - 70.50.01 Remove Before starting, refer to general brake service practice.See Adjustment. NOTE: The non-return valve and grommet are the only serviceable components. In event of failure or damage, fit a new unit. 1.Remove master cylinder.See this Section. 2.Release vacuum hose from servo. 3.Disconnect brake light switch Lucars. 4.Remove 3 screws securing closing panel to lower’A’post. 5.Release closing panel sufficient to gain access to brake pedal return springs. 6.Release 2 brake pedal return springs from brake pedal. 7.Remove blanking grommets from either side of pedal box. 8.Remove split pin and clevis pin securing servo push rod to brake pedal. 9.Remove 2 nuts securing servo to pedal box. 10.Remove servo assembly and rubber washer from pedal box.
70BRAKES 6 REPAIR Refit 11.Fit rubber washer and servo assembly to pedal box. 12.Fit nuts securing servo to pedal box and tighten to14 Nm. (10 lbf.ft) 13.Position brake pedal to servo push rod. 14.Fit clevis pin and NEW split pin to secure brake pedal to servo push rod. 15.Fit blanking grommets to each side of pedal box. 16.Attach pedal return springs to brake pedal. 17.Position closing panel and tighten screws to lower’A’post. 18.Connect vacuum hose to servo. 19.Connect brake switch Lucars. 20.Fit brake master cylinder.See this Section.MODULATOR UNIT - ABS Service repair no - 70.65.49 Remove 1.Position cloth under modulator to absorb any fluid spillage. CAUTION: Do not allow brake fluid to contact paint finished surfaces as paint may be damaged. If spilled, remove fluid and clean area with clean warm water. 2.Disconnect 2 inlet brake pipe unions from pump side of modulator. 3.Disconnect 4 outlet brake pipe unions from top of modulator. CAUTION: Plug the connections. 4.Disconnect 2 multiplugs from rear of modulator. 5.Loosen nut securing rear of modulator to mounting bracket. 6.Remove 2 nuts securing front of modulator to mounting bracket. 7.Release modulator from mounting bracket. 8.Disconnect multiplug from base of modulator. 9.Remove modulator. Do not carry out further dismantling if component is removed for access only. 10.Remove 3 mounting rubbers from old modulator and fit to new.
BRAKES 7 REPAIR Refit 11.Position modulator to mounting bracket and connect multiplug. 12.Fit modulator to mounting bracket and tighten nuts to9 Nm (7 lbf.ft). 13.Connect 2 multiplugs to rear of modulator. 14.Remove plugs from brake pipes and modulator. 15.Clean brake pipe unions. 16.Connect brake pipe unions to modulator ensuring pipes are connected to their correct ports. 17.Tighten all unions to14 Nm (10 lbf.ft). 18.Bleed brake system.See Adjustment. NOTE: To ensure correct operation, the ABS system MUST be tested using TestBook.BRAKE CALIPER - FRONT Service repair no - 70.55.02 Remove 1.Loosen front road wheel nuts. 2.Raise front of vehicle. WARNING: Support on safety stands. 3.Remove road wheel. 4.Remove split pins from pad retaining pins. 5.Remove brake pad retainers and springs. 6.Remove brake pads and shim if fitted. 7.Pull back brake hose shield. 8.Clamp brake hose using a suitable clamp. 9.Position container beneath brake caliper to collect spillage. 10.Loosen brake pipe union and disconnect from caliper. 11.Plug brake pipe and caliper connections. 12.Remove 2 bolts securing caliper. 13.Remove brake caliper.
70BRAKES 8 REPAIR Refit 14.Clean caliper to hub mating faces. 15.Position caliper to hub, fit bolts and tighten to82 Nm (60 lbf.ft). 16.Remove plugs from pipe to caliper connections and wipe. 17.Connect pipe to caliper, tighten union to15 Nm (11 lbf.ft). 18.Apply a light film of grease to rear of brake pads. 19.Fit pads to calipers. From 02MY, ensure pads are correctly fitted, with leading edge chamfer fitted as shown. 20.Fit pad retainers and springs. 21.Fit split pins to retainers. 22.Remove brake hose clamp. 23.Bleed brakes.See Adjustment. 24.Depress brake pedal to seat pads onto discs. 25.Fit road wheels, remove axle stands and tighten nuts to130 Nm (96 lbf.ft).BRAKE CALIPER - REAR Service repair no - 70.55.03 Remove 1.Loosen rear road wheel nuts. 2.Raise rear of vehicle. WARNING: Support on safety stands. 3.Remove road wheel. 4.Remove split pins from brake pad retaining pins. 5.Remove brake pad retaining pins. 6.Remove brake pad retainer springs. 7.Remove brake pads and shim if fitted. 8.Position container beneath brake caliper to collect spillage. 9.Loosen brake pipe union and disconnect from caliper. CAUTION: Plug the connections. 10.Remove 2 bolts securing caliper. 11.Remove brake caliper.
BRAKES 9 REPAIR Refit 12.Clean caliper to axle bracket mating faces. 13.Position caliper to axle bracket, fit bolts and tighten to82 Nm (60 lbf.ft). 14.Remove plugs from pipe and caliper. 15.Clean brake pipe union and caliper. 16.Connect pipe to caliper, tighten union to15 Nm (11 lbf.ft). 17.Apply a light film of grease to rear of brake pads. 18.Fit brake pads. From 02MY, ensure shims are correctly fitted, see illustration. NOTE: Vehicles from 02MY have leading and trailing edge chamfers on rear pads. 19.Fit pad retainer springs. 20.Fit brake pad retaining pins and secure with new split pins. 21.Bleed brakes.See Adjustment. 22.Depress brake pedal to seat pads onto discs. 23.Fit road wheels, remove axle stands and tighten nuts to130 Nm (96 lbf.ft).SWITCH - STOP LIGHT Service repair no - 70.35.42 Remove 1.Disconnect 2 Lucars from stop light switch. 2.Remove mastic from around switch. 3.Remove switch from pedal box. Refit 4.Fit and tighten switch to pedal box. 5.Apply mastic to switch. 6.Connect 2 Lucars to switch.
70BRAKES 10 REPAIR FRONT BRAKE PADS - FROM 02MY Service repair no - 70.40.02 Remove 1.Remove front road wheels. 2.Clean exterior of calipers. 3.Remove split pin from retaining pins. 4.Remove pad retaining pins and anti-rattle springs. 5.Remove brake pads. 6.Clean exposed parts of pistons, using new brake fluid. Wipe away excess with a lint free cloth. 7.Using piston clampLRT-70-500press each piston back into its bore. Ensure that displaced brake fluid does not overflow from reservoir. Refit 8.Fit brake pads. NOTE: Ensure pads are correctly fitted, with leading edge chamfer fitted as shown. 9.Fit pad retaining pins and anti-rattle springs. Secure with new split pins.
BRAKES 11 REPAIR 10.Apply service brake pedal several times to locate pads. 11.Fit road wheels, remove chassis stands and jack. Tighten wheel nuts to130 Nm (96 lbf/ft). 12.Check fluid reservoir. Top up if necessary, using correct grade of fluid.See LUBRICANTS, FLUIDS AND CAPACITIES, Information.REAR BRAKE PADS - FROM 02MY Service repair no - 70.40.03 Remove 1.Remove rear road wheels. 2.Clean exterior of calipers. 90 Models 110/130 Models 3.Remove pad retaining pins and anti-rattle springs. Note differences between 90 and 110/130 models. 4.Remove brake pads and shims.