Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							70BRAKES
14
REPAIR 14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm, 0.2 in projecting from bore.
15.Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16.Using special toolLRT-70-500- piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17.Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18.Fit caliper to axle, tighten bolts evenly to
82 Nm,
60 lbf ft.
19.Connect brake pipe to caliper. Tighten to15 Nm,
11 lbf ft.
20.Remove clamp from flexible brake hose.
21.Insert pads and retaining springs, secure in
position with new retaining pins and spread
ends. Ensure retaining springs are located
correctly.
22.Bleed brake system.
See Brake System Bleed
23.Press brake pedal firmly several times to locate
pads.
24.Fit road wheels, remove axle stands and finally
tighten road wheel nuts,
130 Nm, 95 lbf ft.
25.Road test vehicle.
CAUTION: New brake pads require
bedding-in, for several hundred miles
before brakes are at maximum efficiency.REAR BRAKE DISC
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly.
See REAR AXLE
AND FINAL DRIVE, Repair, Rear hub
assembly
.
2.Remove 5 nyloc nuts securing road speed
sensor ring to disc.
3.Remove sensor ring.
4.Remove disc bolts.
5.Remove disc from rear hub.
Refit
6.Fit disc to rear hub.
7.Apply loctite 270 and fit disc bolts. Tighten to
73
Nm, 54 lbf ft
.
8.Using new nyloc nuts fit sensor ring.
9.Check total disc run out, this must not exceed
0,15 mm, 0.006 in. If necessary reposition disc.
10.Fit rear hub assembly.
See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly
.
Disc reclamation
11.Check disc thickness. The disc may be
machined to minimum thickness of 12 mm,
0.472 in. Machine equal amounts off each face.
NOTE: The brake disc MUST BE renewed if
the minimum running thickness stamped
on the disc is recorded. 
						

							BRAKES
15
REPAIR
TRANSMISSION BRAKE
1.Pin
2.Washer
3.C clip
4.Brake shoe
5.Cable lever
6.Hold down spring
7.Dished washer
8.Brake drum
9.Screw
10.Brake cable
11.Adjuster slide
12.Adjuster nut13.Spring
14.Adjuster slide
15.Adjuster bolt
16.Dished washer
17.Hold down spring
18.Brake shoe
19.Hold down pin
20.Hold down pin
21.Abutment plate
22.Back plate
23.Spring 
						

							70BRAKES
16
REPAIR TRANSMISSION BRAKE SHOES
Service repair no - 70.45.18
Remove
1.Park vehicle on level ground, chock road wheels
and release park brake. Alternatively, raise
vehicle on a ramp.
2.Disconnect rear propeller shaft from
transmission output flange at brake drum.
3.Slacken off transmission brake drum adjustment
bolt.
4.Remove single screw securing brake drum to
output flange.
5.Withdraw drum to expose brake assembly.
6.Release top and bottom springs from brake
shoes.
7.Grip dished washer with a pair of pliers, depress
washer and turn through 90°.
8.Remove dished washer, complete with hold
down spring and pin from both shoes.
9.Move brake shoes out from adjuster slides,
release from abutment plate and remove from
backplate.
10.Check that springs are satisfactory for continued
use.
NOTE: If new brake shoes are to be fitted,
the springs should also be renewed.Refit
11.Locate RH brake shoe in slide and secure brake
shoe and lever assembly to backplate with hold
down pin, spring and dished washer.
12.Locate LH brake shoe in slide and fit abutment
plate between both brake shoes. Secure LH
shoe with hold down pin, spring and dished
washer.
13.Fit pull-off springs to brake shoes.
14.Fit brake drum. Tighten screw to
25 Nm, 18 lbf
ft.
15.Check that park brake lever is released.
16.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
17.Tighten adjuster bolt to
25 Nm, 18 lbf ftto
ensure brake drum is locked.
18.Slacken off adjuster bolt by 1¼ turns to give
shoes a running clearance. Check that the drum
is free to rotate.
19.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm, 34 lbf ft.
20.Remove wheel chocks and check operation of
park brake. 
						

							BRAKES
17
REPAIR PARK BRAKE CABLE
Service repair no - 70.35.25
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on ramp [hoist].
2.From inside vehicle, pull up handbrake gaiter.
3.Remove split [cotter] pin, clevis pin, washer and
disconnect cable from park brake lever.
4.Slacken off transmission brake drum adjusting
screw.
5.Disconnect propeller shaft from output flange.
6.Remove retaining screw and withdraw brake
drum.
7.Release park brake cable clevis from abutment
on cable lever, see J6337, and pull through
aperture in back plate.
8.Pull cable from heelboard and remove from
vehicle.Refit
9.Feed new cable through heelboard ensuring
rubber grommet is correctly located.
10.Position cable over guide plate, insert through
backplate and connect to cable lever.
11.Fit cable to park brake lever and secure with
clevis pin and split [cotter] pin.
12.Fit brake drum. Tighten screw to
25 Nm, 18 lbf
ft.
13.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
14.Tighten adjuster bolt further to
25 Nm, 18 lbf ft
to ensure brake drum is locked.
15.Slacken off adjuster bolt by 1¼ turns to give
brake shoes running clearance. Check that the
drum is free to rotate.
16.Slacken locknut and adjust cable to give the
park brake pawl 2 notches free movement on the
rachet before being fully operational on 3rd
notch (brake shoes are fully expanded against
drum).
NOTE: Cable adjustment is for a new cable
or to compensate for cable stretch. Cable
adjustment must not be used to take up
brake shoe wear.
17.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm, 34 lbf ft.
18.Remove wheel chocks and check operation of
handbrake. 
						

							BRAKES
1
OVERHAUL
Key to master cylinder
1.Water ingress seal
2.Transfer housing
3.Vacuum seal
4.Guide ring
5.Retaining ring
6.O ring seal
7.Primary plunger assembly
8.L seal
9.Secondary plunger10.Washer
11.Recuperating seal - primary cup
12.Seal retainer
13.Springs - 2 off
14.Swirl tube
15.Master cylinder body
16.Reservoir seals
17.Reservoir
18.Low fluid level switch and cap 
						

							70BRAKES
2
OVERHAUL MASTER CYLINDER
Service repair no - 70.30.09
Before starting overhaul procedure refer to general
brake service practice.
See Repair, General brake
service practice
Dismantling master cylinder
1.Disconnect battery and remove master cylinder
from servo
See Repair, Master cylinder
2.Before commencing overhaul procedure
thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
3.The reservoir is a push fit in master cylinder and
secured by seals. Carefully ease reservoir from
master cylinder by rolling it from seals as
illustrated.
4.Using soft jaws, one either side of master
cylinder flange and clamp flange in a suitable
vice. Remove water ingress O ring seal from
master cylinder to servo flange and discard.
5.Hold outside of transfer housing with a suitable
pair of grips, carefully pull, while working pliers in
a backwards and forwards rocking motion to
ease housing off master cylinder, discard
housing and vacuum seal.
6.Withdraw 2 reservoir seals from master cylinder
inlet ports, seals are different and should be
noted for assembly. Discard both seals.
7.Remove retaining ring and O ring seal from
machined outer surface of master cylinder,
discard both seal and retaining ring. 
						

							BRAKES
3
OVERHAUL
8.Remove guide ring from mouth of master
cylinder which supports primary plunger
assembly and place to one side, this component
is not part of master cylinder service kit and is to
be refitted on assembly of unit.
9.Pull primary plunger assembly out of master
cylinder.
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
10.The secondary plunger assembly will remain at
bottom of master cylinder bore, plunger can be
easily expelled by tapping assembly on a piece
of timber until plunger appears at cylinder mouth,
carefully pull plunger out of master cylinder.
11.If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
expel it from bottom of master cylinder bore and
discard.12.Clean all parts with Girling cleaning fluid or
unused brake fluid and place cleaned parts on to
a clean sheet of paper. Inspect cylinder bore and
plungers for signs of corrosion, ridges and score
marks. Provided working surfaces are in perfect
condition, new seals from a Girling Service
repair kit may be used.
Renewing secondary plunger seals
13.Remove following components from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded and polished is required to
remove L seal. DO NOT damage
secondary plunger. A. Springs B. Seal retainer C.
Recuperating seal (primary cup) D. Washer E. L
seal
14.Coat new seals in unused brake fluid and firstly
fit L seal to plunger.
15.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated. 
						

							70BRAKES
4
OVERHAUL Assembling master cylinder
CAUTION: It is important that the following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
NOTE: Thoroughly check that no debris is
lodged in fluid passageways and drillings.
If debris is found, carefully remove,
re-clean cylinder and re-check.
16.Fit new swirl tube to bottom of cylinder bore.
17.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
18.Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19.Fit original guide ring to support primary plunger.
20.Coat a new O ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: O ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.21.Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22.Fit two new reservoir seals in ir respective ports.
23.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24.Lubricate vacuum seal with brake fluid, fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange. Do
not adjust transfer housing after fitting.
25.Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27.Fit master cylinder to servo.
See Repair,
Master cylinder
28.Reconnect battery, and road test vehicle. 
						

							BRAKES
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Brakes Nm lbf ft
Brake pipe connections to:
- Pressure reducing valve 15....................................... 11
- Brake calipers 15....................................................... 11
- Master cylinder 15...................................................... 11
Flexible hoses to calipers 15................................................. 11
Bleed screws 15.................................................................... 11
Brake caliper to swivel pin housing 82.................................. 60
Brake disc bolts* 73.............................................................. 54
Brake drum screw 25............................................................ 18
Rear propeller shaft flange 46............................................... 34
Brake drum adjuster bolt 25.................................................. 18
Servo assembly to pedal box 26........................................... 19
Pedal box to engine bulkhead 25.......................................... 18
Master cylinder to servo 26................................................... 19
Road wheels 130.................................................................... 95
* Apply Loctite 270 before assembly 
						

							WHEELS AND TYRES
1
DESCRIPTION AND OPERATION TYPES OF WHEEL RIMS AND TYRES
Description
The vehicle is equipped with alloy wheels and
tubeless radial ply tyres.
Tyre codes
The writing, codes and numbers moulded into the tyre
wall vary between tyre manufacturers, however most
tyres are marked with the information shown in the
illustrated example.
NOTE: The illustration is an example of the
type of markings moulded into tyres and is
for guidance only. For specific tyre
specifications
See GENERAL SPECIFICATION
DATA, Information, Tyre size and pressures
.1.Type of tyre construction -Radial Ply
2.Load index -104
3.Speed symbol -SorT
4.USA Tyre quality grading -Tread wear 160
Traction A temperature B
5.Tread wear indicators moulded into tread pattern
are located at intervals around the tyre and
marked by a code -E66 103S6
6.Tyres with Mud Snow type tread pattern are
marked -M&S
7.Tyre reinforcing mark -Reinforced
8.USA Load and pressure secification -
1260Kg(2778LBS) at 450kPa (65psi)
9.Tyre size -265/75 R16 All Terrain
10.Type of tyre -TUBELESS
11.Country of manufacture -MADE IN GREAT
BRITAIN
12.USA Compliance symbol and identification -
DOT AB7C DOFF 267
13.European type approval identification -E11
01234
14.Tyre construction -SIDE WALL 2 PLIES
RAYON. TREAD 2 RAYON 2 STEEL
15.Manufacturers brand name/type -TRACTION
PLUS mzx M