Land Rover Defender 90 110 Workshop 1984 Rover Manual

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...

BRAKING SYSTEM I70 I 
.. ,. Renewing secondary  plunger seals 
14. Remove the  following items from the plunger: 
f ,*: 
(a) spring 
(b)  seal  retainer 
(c)  recuperating seal 
(d)  washer 
outer  seal. 
15. Taking care  not to damage  the plunger  prise off the 
a 
 b d 14 \I I 
. :: 
I C 
I 
I 
15 
ST1198M 
16. Fit a new  outer  seal using  the  same  procedure  as 
for  the  primary  plunger outer seal by  squeezing  the 
seal  between  the finger  and  thumb into  an  ellipse 
and  press  the raised...

BRAKING SYSTEM 
Incorrect linings. Badly lined shoes.  Distorted 
shoes.  Overloaded  vehicle. Excessive 
braking.  Old hydraulic fluid. 
BRAKING  SYSTEM 
FAULT  DIAGNOSIS 
Replace the shoes,  decrease vehicle load or renew hydraulic  fluid as necessary. 
FAULT I CAUSE I ACTION 
Air in system. Badly lined shoes. Shoes 
distorted or incorrectly  set. Faulty  drums. 
Weak  master  cylinder  mounting. 
FADE 
Check for air in the system  using a Hose Clamp 
and  bleed if necessary.  Check the master...

~.. .:...:;, : ..1 . ... ... :) 
.I..... ..l.l. . . . . ,.. , . .....,. I. ; ... , ..  

76 
c 
8 
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CHASSIS AND BODY 
7- 
2 m m 
D 3 
2  

CHASSIS AND BODY 
A FrontDatum 
B Chassis Datum 
C  Front  axle centre  Iine 
D Rear axle centre  line 
1. 239,O-236,5 mm 
2. 82,O-79,5 mm 
3. 633 mm 
4. 2420,6-2418,6 mm 
5. 2306,4-2305,4 mm 
6. 981,2-978,7 mm 
7. 182,7 mm 
8. 41,5-37,O mm 
9. 252-250 mm - . .. 10. 110 mm 
11. 2360 -Wheelbase 
12.  636 - 654 mm 
13. 488-483 mm 
14. 488-483 mm 
15. 3431,l-3426,l mm 
16. 588,3 - 586,3 mm 
17. 2313,8-2311,8 mm 
18. 590,5 mm 
19. 295,25 mm 
20. 519,60 - 517,OO mm 
21. 259,80-258,50 mm 
22. 1242,6 - 1240,6...

76 
N 
CHASSIS AND BODY 
pi 
I a 
4