Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							REAR SUSPENSION
3
REPAIR SUSPENSION LINK - LOWER
Service repair no - 64.35.02.
Remove
1.Site vehicle on a ramp [hoist].
2.Alternatively, support vehicle on stands under
rear axle.
3.Remove lower link rear fixings.
4.Remove mounting bracket fixings at side
member bracket.
5.Remove lower link complete.
6.Remove locknut.
7.Remove mounting bracket from lower link.Renew bush
8.Press out rubber bushes.
9.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10.Fit mounting rubber to lowerlink.
11.Secure mounting rubber to chassis bracket, but
do not fully tighten locknut.
12.Fit lower link to axle mounting and secure fixing
to
175 Nm, 130 lbf ft.
13.Lower vehicle, allow axle to take up static laden
position, and fully tighten link chassis fixing to
175 Nm, 130 lbf ft. 
						

							64REAR SUSPENSION
4
REPAIR ANTI-ROLL [SWAY] BAR
Service repair no - 64.35.08
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll [sway] bar.
2.Remove 4 nuts, bolts and washers securing 2
bush straps to chassis mountings.
3.Remove nuts, bolts, washers and rubber bushes
from the ball joint links.
4.Remove anti-roll [sway] bar.Refit
5.Position rubber bushes on anti-roll [sway] bar. Fit
joint towards axle.
6.Fit anti-roll [sway] bar with 2 straps. Ensure ball
joint link arms point down as shown in J6259.
Loosely fit, bolts, washers and NEW nyloc nuts.
7.Fit bolt, washers and rubber bushes. Fit anti-roll
[sway] bar to ball joint links and tighten to
68Nm,
50 lbf ft
.
8.Tighten nuts securing straps to
30Nm, 22 lbf ft. 
						

							REAR SUSPENSION
5
REPAIR ANTI-ROLL [SWAY] BAR BALL JOINT LINKS
Service repair no - 64.35.24.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from ball joint links and lower anti-roll
[sway] bar to clear links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release ball joint using special tool18G
1063Aas shown.
4.Remove castellated nut and ball joint link.
Refit
5.Fit ball joint link arm and castellated nut. Point
ball joint link arm down as shown. Tighten fixing
to
40 Nm, 30 lbf ftand fit new cotter pin.
6.Align anti-roll bar to ball joint links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll [sway] bar
to ball joint links. Tighten to
68Nm, 50 lbf ft. 
						

							REAR SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Rear Suspension
Nm lbf ft
Anti-roll [sway] bar:
- Strap nyloc nuts 30.................................................... 22
- Ball link self lock nut 68.............................................. 50
- Castellated nut 40...................................................... 30
Top link to mounting bracket 175............................................ 130
Bottom link to axle 175............................................................ 130
Bottom link to chassis 175...................................................... 130
Top link bracket to rear cross member 47............................. 35
Shock absorber to axle 37.................................................... 27
Road wheel nuts 130.............................................................. 95 
						

							BRAKES
1
DESCRIPTION AND OPERATION DESCRIPTION
The mechanical components of the hydraulic braking
system consist of four piston caliper disc brakes at the
front and two piston caliper disc brakes at the rear.
The front brake discs are vented.
A cable controlled parking brake operates a single
drum brake mounted on the rear output shaft of the
transfer gearbox and is completely independent of the
main braking system.
The basic hydraulic system involves 2 separate and
independent primary and secondary circuits which
permits a degree of braking should a fault occur in
one of the circuits. The primary circuit operates the
rear brake calipers and the secondary circuit the front
brake calipers.Master cylinder
A tandem master cylinder, which is assisted by a
lightweight compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
Master cylinder components
1.Secondary plunger
2.Secondary spring
3.Recuperation seal - secondary
4.Primary spring
5.Recuperation seal - primary
6.Primary plunger 
						

							70BRAKES
2
DESCRIPTION AND OPERATION When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank. When the
footbrake is applied, the primary plunger assembly
moves up the cylinder bore and the pressure created
acts in conjunction with the primary spring to
overcome the secondary springs, thus moving the
secondary plunger assembly up the bore at the same
time. Initial movement of both plungers takes the
recuperating seals past the cut-off holes in the
cylinder chambers A and C, and applies pressure to
the fliud in those chambers, which is directed to the
respective cylinders of each of the separate circuits.
The fluid in chambers B and D is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers A and C
and the recuperation seals.The recuperation seals momentarily collapse allowing
fluid in chambers B and D, which is unaffected by
the movement of the plungers, to flow through the
holes in the plungers, over the collapsed seals and
into chambers A and C respectively. The movement
of fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers A and C to move through the cut off holes
into the fluid reservoir.
The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied.
Vacuum is obtained from the depression in the inlet
manifold. The vacuum is applied to both sides of a
flexing diaphragm and by admitting atmosheric
pressure to the rear diaphragm, assistance is
obtained. The servo unit is mounted between the
brake pedal and master cylinder and is linked to these
by push rods. Should a vacuum failure occur, the two
push rods will act as a single rod allowing the brakes
to function in the normal way, although more effort will
be required to operate the brake pedal. 
						

							BRAKES
3
DESCRIPTION AND OPERATION Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate
momentarily when ignition is switched on and
indicates that the warning circuit is functioning
correctly. A hydraulic failure in the system will result in
fluid loss, causing the warning light to illuminate.A pressure reducing valve (PRV), fitted to the RH
bulkhead in the engine compartment, maintains the
braking balance, see J6322. Pressure to the rear
calipers is regulated by the PRV, this valve is of the
failure by-pass type allowing full system pressure to
the rear brake calipers in the event of a front
(secondary) circuit failure.
A.Primary circuit
B.Secondary circuit
C.Pressure reducing valve (PRV)1.LH rear brake caliper
2.T-connector
3.RH rear brake caliper
4.Brake servo
5.Master cylinder and reservoir
6.LH front brake caliper
7.RH front brake caliper 
						

							BRAKES
1
REPAIR GENERAL BRAKE SERVICE PRACTICE
Brake fluid precautions
WARNING: Do not allow brake fluid to
come into contact with eyes or skin.
CAUTION: Brake fluid can damage
paintwork, if spilled wash off immediately
with plenty of clean water.
CAUTION: Use only correct grade of brake
fluid. If an assembly fluid is required use
ONLY brake fluid. Do NOT use mineral oil,
i.e. engine oil etc.
CAUTION: Thoroughly clean all brake
calipers, pipes and fittings before
commencing work on any part of the brake
system. Failure to do so could cause foreign
matter to enter the system and cause damage to
seals and pistons which will seriously impair the
efficiency of the brake system. To ensure the
brake system efficiency is not impaired the
following warnings must be adhered to :-
·DO NOT use any petroleum based cleaning
fluids or any proprietary fluids containing
petrol.
·DO NOT use brake fluid previously bled from
the system.
·DO NOT flush the brake system with any fluid
other than the recommended brake fluid.
The brake system should be drained and flushed
at the recommended service intervals.
Cover all electrical terminals carefully to make
absolutely certain that no fluid enters the
terminals and plugs.FLUID LEVEL CHECK / TOP-UP
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
1.Park vehicle on level ground.
2.Check level is between MIN and MAX marks.
3.If level is below MIN mark top up fluid level to
MAX mark on reservoir, using correct fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Brake fluid reservoir
CAUTION: Do not fill reservoir above
maximum line. 
						

							70BRAKES
2
REPAIR BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.
See General Brake Service
Practice
·During bleed procedure, brake fluid level must not
be allowed to fall below the MIN level. Keep
reservoir topped to the MAX level.
·To bleed the hydraulic circuits, four bleed nipples
are provided, one at each caliper.
·There are two methods by which air can be
removed from the braking system:-
1. MANUAL BLEED PROCEDURE.
2. PRESSURE BLEED PROCEDURE.
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lbf/in
2.
Manual bleed procedure
Equipment required
·Clean glass receptacle
·Bleed hose
·Wrench
·Approx 2 litres brake fluid
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
Master cylinder bleed
1.Disconnect battery.
2.Depress brake pedal fully and slowly 5 times.
3.Release the pedal and wait for ten seconds.
4.Air bubbles will rise into the reservoir during
these instructions.
5.Repeat instructions until a firm resistance is felt
at the pedal.
Complete circuit bleed
1.Fit bleed hose to any caliper bleed screw.
2.Dip free end of bleed hose into brake fluid in
bleed bottle.
3.Open bleed screw of caliper.
4.Depress brake pedal fully several times until fluid
is clear of air bubbles.
5.Keeping pedal fully depressed, tighten bleed
screw, then release pedal.
6.Repeat the above procedure on remaining 3
calipers.
7.Fit all bleed screw protection caps.
8.Check/top-up fluid level when bleeding is
complete.
See Fluid Level Check / Top-Up 
						

							BRAKES
3
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Before starting repair refer to general brake service
practice
See General Brake Service Practice
Remove
1.Disconnect battery.
2.Place a container under the master cylinder to
catch escaping brake fluid.
3.Clean area round master cylinder ports.
4.Disconnect pipes from master cylinder ports.
Cover, not plug, the pipe ends to prevent entry of
dirt.
5.Disconnect electrical leads from reservoir cap.
6.Remove two nuts securing master cylinder to
servo and withdraw cylinder.
7.Remove reservoir cap and drain fluid into
suitable container for disposal.
8.The reservoir is a push fit in the master cylinder
and secured by seals. Carefully ease the
reservoir from the master cylinder by rolling it
from the seals. Note that the two seals are
different in size.Refit
9.Insert new reservoir seals in the master cylinder
ports and fit reservoir to master cylinder.
10.Ensuring that water ingress seal is in position, fit
master cylinder to servo. Tighten fixings to
26
Nm, 19 lbf/ft.
11.Connect brake pipes to master cylinder ports
and tighten to
15 Nm, 11 lbf/ft.
12.Fit electrical leads to reservoir cap
13.Fill reservoir with recommended brake fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
14.Bleed the brake systemSee Brake system
bleed
15.Reconnect battery and road test vehicle.