Land Rover Defender Workshop 1993 Rover Manual

BRAKING SYSTEM 
REMOVE AND OVERHAUL  BRAKE CALIPERS 
Special  tool: 
18G672 
- LRT-70-500 - Piston  clamp 
Remove  caliper 
1. Slacken the  wheel  retaining nuts, jack-up  the 
vehicle,  lower onto  axle  stands  and remove 
the  wheels. 
2. Expose  the  brake  flexible  hose by  moving the 
coiled  protective covering  and clamp  the hose. 
Disconnect the  hose from  the  caliper. 
NOTE: Three different  methods  of retaining  the 
brake  pads  are  used. Each  type  is listed 
below 
and shown in the...

KEY TO CALIPER 
1. Bleed  screw 
2  Caliper 
3.  Hold  down  springs. 
4.  Retaining  pins and clips 
5.  Friction  pads. 
6.  Brake  disc. 
7.  Piston. 
8.  Wiper  seal retainer. 
9.  Wiper  seal. 
or 
split  pins. 
10.  Fluid seal. 
ST2721M  

BRAKING SYSTEM 
Slide the assembly,  seal first, over the 
Do not  separate the  caliper halves. protruding  piston and into the bore  recess 
Remove  the piston  clamp  from the mounting 
half  and  use the clamp  to press  home 
the 
seal retainer  and piston. 
5. Clean  the outer  surfaces  of the  caliper  with 
methylated  spirit. 
6. Using special  tool 18G672, clamp  the pistons 
in  the  mounting  half 
of the caliper  and gently, 
keeping  fingers clear, and 
with CAUTION, Mounting-half  pistons...

BRAKING SYSTEM 
OVERHAUL REAR BRAKES  - 110  models 
DISMANTLING 
7.  Remove  the two dust covers. 
WARNING: Do not use  an air  line to blow dust 
from  the  brake  assemblies  - asbestos  dust  from 
brake  linings  can be a serious  health 
risk if 11. Clean  components  with  Girling cleaning  fluid 
inhaled.  and allow  to dry. 
12. Examine  the cylinder  and pistons  for 
1. Slacken  the  road  wheel  nuts,  jack-up  the corrosion,  scores  and  wear.  Renew  any 
component  that is not...

BRAKING SYSTEM 
20. The 
shoes  in the  wheel  cylinder piston  slots 2. Disconnect the  propeller  shaft  from  the output 
and  lever  the  opposite  ends  into the pivot  flange. 
block. 
3. Remove  the two screws and withdraw  the 
21.  Operate  the snail  cams 
to check  that the  brake  drum. Skim if excessively  scored or 
shoes  respond.  oval. 
22.  Connect  the  brake  fluid pipe to  the  wheel  4. Remove the  split pin and  clevis  pin  connecting 
cylinder. 
23. 
Fit the  brake  drum and...

BRAKING SYSTEM 
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.  TDO106,254,254  Remove the  locking  plate. 
11.  Remove  the packing  plate and withdraw  the 
expander assembly from  the  back
-plate. 
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....

BRAKING SYSTEM 
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...

4. Remove the two  bolts  securing  brake caliper 
to the swivel  housing  and  withdraw the 
caliper 
. 
BRAKING SYSTEM 
RENEWING  FRONT BRAKE  DISCS 5. Remove  the  front  hub  complete  with brake 
disc  by following  instructions 
6 to 14 in 
Removing SECTION 54 for front hub overhaul. 
6. Remove  the five  bolts to separate  the disc 
1. Disconnect  the battery.  from the  hub. 
2. Jack-up vehicle,  lower  on to axle  stands  and 
remove  road wheels. 
3. Disconnect  the  brake pipe union  from  the...

BRAKING SYSTEM 
Fitting 
8. Make sure that disc  and hub  mating  faces are 
clean  and 
free from burrs or any other 
irregularities  that could  cause  the disc  to run 
out excessively. 
9. Assemble  the disc to the  hub  with  the five 
bolts  and tighten  evenly 
to the correct  torque. 
12. Continue  with instructions  32 
to 41, SECTION 
54. 
10. Fit the hub  and disc  assembly to the axle  by 
following  instructions  24 
to 31, SECTION 54. 
11. Mount  the dial  test  indicator  bracket RO...

BRAKING SYSTEM 
OVERHAUL MASTER CYLINDER  - Lucas Girling  - 
Type 
25.4 mm  AS/AS 
Dismantling  master cylinder 
1. Disconnect  the battery  and  remove  the master 
cylinder  from the servo. 
WARNING:  Use only  clear  methylated  spirit  or 
unused  brake  fluid to  clean  all  parts  of the  brake 
system.  DO NOT  use  petrol,  kerosene  or other 
mineral  based fluids. 
2. Before commencing  the  overhaul  procedure 
thoroughly  clean the  master  cylinder  and 
6. Withdraw  the two reservoir...