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 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  
						

							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  part 
of the seal  over  the flange 
using  the fingers 
of the  other  hand. 
17. Fit  the  recuperating  seal  assembly parts in the 
reverse  order 
of removal. 
Assembling  master cylinder 
It is important  that  the following  instructions  are 
carried  out precisely,  otherwise  damage  could be 
caused  to the new seals  when  inserting  the plungers into 
the  cylinder  bore.  Generous amounts of  new brake 
fluid  should  be  used 
to lubricate  the  parts during 
assembly.  Never use old fluid  or any  other  form 
of 
cleaning  and lubricating  material.  Cleanliness 
throughout  is essential. 
18. Clamp  the cylinder  in a vice and lubricate  the 
secondary  plunger  seals  and cylinder  bore. Offer 
the  plunger  assembly  to the  cylinder  until the 
recuperation  seal 
is resting  centrally  in the  mouth 
of the  bore.  Gently  introduce  the plunger  with a 
circular  rocking motion,  as  illustrated. Whilst 
ensuring  that the  seal  does not become  trapped, 
ease  the  seal into  the  bore  and slowly  push the 
plunger down  in one  continuous movement. 
-k ss. 
II 18 
ST 1 ZOOM 
19. 
20. 
21. 
22. 
23. 
24. 
Fit  the  primary  plunger assembly  using the same 
method  as  for the  secondary  plunger.  Press  the 
plunger  down  and  secure the assembly  with 
the 
plastic circlip. 
Slowly  press the plunger  down  the bore and  fit the 
secondary  plunger stop
-pin. 
Lubricate  new seals  and 
fit to the inlet  ports  (large 
diameter  downwards). 
Press  the reservoir  into position  and secure  with 
the 
two m!I pins. 
Fit  a new  washer  to the  reservoir  cap and  press  the 
plastic baffle  into position inside  the cap. 
Fit  a new  rubber seal  to the  cylinder  flange and  fit 
the  master  cylinder to  the servo  and  secure  with 
two nuts  and spring  washers. 
ST1199M 
13  
						

							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 
cylinder  mounting, lined shoes  and drums 
and replace 
as necessary. Renew the hydraulic 
fluid if appkdblc. 
Brakes  maladjusted. No clearance  at master 
cylinder  push rod. Seals swollen. Siezed pistons. 
Shoe  springs weak 
or broken. Servo faulty. 
SPONGY 
PEDAL 
Check the brake adjustment.  Check for clearance 
at the master  cylinder, siezcd pistons or weak 
shoe  springs.  Repair or replace parts as necessary. 
HARD 
PEDAL- POOR  BRAKING 
BRAKES PULLING 
FALL  IN FLUID LEVEL 
LONG 
PEDAL 
Incorrect linings. Glazed linings.  Linings  wet, 
greasy or not  bedded  correctly. Servo unit inoperative.  Siezed caliper pistons. 
Worn shock  aborbers causing wheel  bounce. 
Siezed  pistons.  Variation  in linings.  Unsuitable 
tyres 
or pressures.  Worn shock  absorbers. 
Loose brakes.  Greasy linings. Faulty drums, 
suspension 
or steering. Contaminated  seals. Replace 
the shoes, 
or if glazed,  lightly rub down 
with  rough  sandpaper.  Check caliper  for damage 
and repair 
as necessary.  Check servo. 
Fit new  shock absorbers. 
Check 
thc tyres and pressures,  seized pistons, 
greasy linings, or loose brakes;  then check 
suspension, steering  and drums. Repair 
or replace as necessary. Fit new  shock 
absorbers. Recti@ contamination,  fit new seals 
and  hoses. 
Chcck the pads  for wcar and for hydraulic  fluid 
Worn  disc pads. External leak. Leak  in Scrvo 
A. 
Disc  Brakes 
Discs  running  out 
pushing  pads back. 
Misplaced  dust covers. 
B. Drum Brakes 
Brakes  need adjustment. 
Fluid  leak. 
Fluid  contamination.  Wom 
or swollen seals in master cvlinder. Blocked  filler caD vent.  ~~~~~~~~~  ~ 
UNEVEN 
OR EXCESSIVE 
PAD  WEAR  A. 
Check  the disc 
run out  does  not exceed 0,lO mm (0.004 in) 1. Rotate  the disc on the hub. 2. Check  the didhub mounting  faces. 
and  for fluid  leaks.  Adjust brakes, repair leak, 
if necessary, or renew  seals and change  fluid. 
B. Check the brake  adjustment,  filler cap vent 
Disc  corroded (by  salt). Disc badly  scored. Pads 
scored.  Pads require  interchanging.  Incorrect 
friction  material.  Check 
the disc 
for corrosion. or scoring  and 
replace if necessary.  Alternatively,  interchange 
pads. Fit new  pads  with correct  friction  material. 
BRAKES BINDING 
1 Unit. I leakage. 
DISC  BRAKE 
SQUEAL- PAD RATTLE 1 Worn retaining pins.  Worn discs.  Renew the 
retaining pins, or discs.  Apply  disc I brake lubricant  to back of pads. 
14  
						

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.I..... ..l.l. . . . . ,.. , . .....,. I. ; ... , ..  
						

							76 
c 
8 
- 
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 mm 
23. 6423-66393 mm 
24. 750,9 mm 
LAND ROVER 90 
CHASSIS ALIGNMENT DIMENSIONS 
25. 639,5-436,5 mm 
26. 136,5 mm 
27. 299,5-295,5 mm 
28.  103 - 100 mm 
29. 131,5-- 126,5 mm 
30. 7053 - 7043 mm 
31. 7053 - 7043 mm 
32. 42,2-40,2 mm 
33. 491 - 486 mm 
34. 594,2-593,4 mm 
35. 283,O-2282,2 mm 
36. 32,25 - 31,25 mm 
37. 397 - 395 mm 
3  
						

							76 
N 
CHASSIS AND BODY 
pi 
I a 
4