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  illustrations  referred to: 
Type 
A - Plate  anti-rattle springs - Fig. ST1157M. 
Type 
B - Wire  anti-rattle  springs - Fig. ST1810M. 
Type  C 
- Coil anti-rattle  springs - Fig. ST3441 
3.  Removing 
friction pads - plate type 
anti-rattle  springs 
Straighten  the splayed  ends 
of the pad 
retaining  pins and withdraw  the pins.  Collect 
the  anti
-rattle  springs  and withdraw  the  pads. 
If the same  pads are to be refitted,  identify 
them  for  assembly 
to their original  locations. 
Removing  friction 
pads - wire or coil 
anti
-rattle  springs 
Remove  the 
four spring  clips  or split  cotters 
and  remove  the  retaining  pins.  Withdraw  me 
friction  pads. 
If the same  pads  are to be 
refitted,  identify  them 
for assembly  to  their 
original  locations. 
4. Remove  the two bolts and  withdraw  the 
caliper  from the  vehicle.  
						

							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 
apply air pressure to the  fluid  inlet port to 
expel  the rim half  pistons.  Since 
it is unlikely 
that  both  pistons  will expel  at the  same  time, 
regulate  the rate 
with a suitable  piece of  to 13. 
timber between  the appropriate  piston and 
caliper. 
7. Finally,  remove  the pistons  keeping  them 15. Fit the  caliper  to the  axle  and secure  with the 
identified  with their  respective  bores. 
two bolts tightening  evenly to the  correct 
8. Remove  the wiper  seal retainer  by inserting  a  torque, see data. 
blunt  screw  driver between  the retainer  and 
16. Connect  the brake  flexible  hose to the  caliper 
the  seal  and prise  the retainer  carefully  from  and remove  the hose  clamp. 
the  mouth  of the  bore. 
17. Lightly  Smear the back and edges of the pads 
9. Taking  care not to damage  the seal  grooves, with disc brake  lubricant  carefully  avoiding the 
extract  the wiper  seal and fluid  seal.  friction 
material. 
10. Clean the bores,  pistons  and particularly  the 18. Fit the friction pads  and secure  using new 
seal  grooves 
with clean  brake  fluid or  pins and split  pins and anti-rattle  springs. 
methylated  spirit only. 
If the caliper  or pistons  Splay the ends of the  early type retaining 
are  corroded 
or if their  condition  is not perfect pins. 
the  parts 
must be renewed. 
14. Clamp  the rim-half  pistons  and carry  out the 
same  procedure  as 
for removing and fitting 
the  rim half  pistons  and seals,  instructions 
6 
Fit  calipers  and  pads to vehicle 
Assemble rim-half pistons 
11. Coat  a new fluid seal  with Lockheed  disc 
brake  lubricant.  Ease the seal  into 
the groove 
in  the  bore  using  only the fingers  and ensure 
that it is properly  seated. The fluid  seal and 
the  groove  are not 
the same  in section so that 
when the  seal  is seated it feels  proud to the 
touch  at the  edge  furthest  away 
from the 
mouth 
of me  bore. 
12. Smear  the appropriate  piston with hydraulic 
brake  lubricant  and insert 
it squarely  into the 
bore  by hand  only. 
Do not tilt the piston 
during  insertion  and leave  approximately 
- mm 
projecting  from the bore. 
13. Coat  a new  wiper  seal with hydraulic  brake 
lubricant  and fit it to  a new  seal retainer.  19. 
Bleed 
the brake  hydraulic  system as 
described  later 
in this section. 
28. 
When the foregoing instructions  have been 
completed  on both 
calipers, depress  the brake 
pedal 
firmly several  times to locate  the friction 
pads. 
21. Fit the  road  wheels,  remove the axle  stands 
and  finally  tighten  the road  wheel 
nuts, see 
data. 
22. Road  test the vehicle.  remembering that  if 
new friction pads have been fitted they are not 
‘bedded  - 
in and may  take  several  hundred 
miles  before  the brakes  are 
at maximum 
efficiency.  
						

							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  satisfactory  or replace 
complete cylinder  assembly. 
2. Slacken  the two brake  shoe  adjusters  on the 13. Fit  new  seals  to the  pistons  noting  that  the 
brake  drum.  14.  Lubricate  the  pistons with new  clean  Girling 
3. Disconnect  the brake  fluid  pipe  to  the wheel 
ingress  of dirt.  16.  Fit the  dust  covers. 
4.  Remove  the two retaining  nuts  and  withdraw 
the  wheel  cylinder 
from the  back-plate. 
Dismantle  and overhaul  wheel cylinder 
8. Withdraw  the  pistons and discard  seals. 
9. Remove  the  spring. 
10. Remove the bleed  screw. 
vehicle,  lower  onto axle stands  and remove 
the  road  wheels. 
rear  of the  back
-plate  to  assist  removal of  seal lip is towards the  cylinder. 
brake  fluid. 
cylinder  and cover  the pipe  end  to prevent  15. 
17. 
Fit the  bleed  screw and tighten  to 
0,5 to 
0,8 kgf m. 
Fit  the spring between  the two pistons. 
Assembling  rear brake 
5. Remove  the  single  retaining  screw  and 18. Fit  the  wheel  cylinder to the  back-plate  and 
6* Assemble new brake  shoe pull-off  springs  to 
secure  with  the 
two nuts  and spring  washers. 
relined  brake shoes  as  illustrated. 
withdraw 
the brake  drum. 
position  of the  pull-off springs. 
Lever 
off the  brake  shoes  whilst noting  the 
19.  
						

							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 secure  with  the  single 5. Remove  the  brake  shoes  complete  with 
screw.  pull
-off springs.  Note  position of springs  in 
24.  Adjust  each  brake  shoe  independently as relation to the  shoes. 
follows: turn  one adjuster  until the shoe  is  6. 
Remove  the four  bolts  securing  back-plate to 
locked  against  the drum.  Back 
off transfer  box and  withdraw  the  back-plate 
approximately 
two serrations  of the  snail  cam  complete  with oil catcher. 
so that  the drum  revolves freely. 
25.  Repeat  instruction  24 on  the  second  shoe  and 
carry  out  the same  procedure  for the  opposite 
brake. 
1. Brake  drum. 
26.  Bleed  the brakes.  2. 
Brake drum  retaining screws 
27.  Fit  the road  wheels,  remove  the  axle  stands 
3. Brake shoes. 
4.  Brake shoes  pull
-off springs. 
6. Adjuster  assembly. 
8. Oil catcher. 
9. Back  plate and retaining bolts. 
10.  Dust cover.  the 
drawlink  to the  actuating  lever. 
KEY TO TRANSMISSION  BRAKE 
and finally  tighten  the road  wheel  nuts to the 
correct  torque. 
5. Expander assembly. 
OVERHAUL  TRANSMISSION  BRAKE 7. Draw  link. 
WARNING: Do not use  an air  line  to remove dust 
from  the brake  assembly.  Asbestos dust from  the 
brake  linings  can 
be a serious  health risk, if 11. Locking  plate. 
inhaled. 12. Packing plate. 
DISMANTLING 
13. Spring  plate. 
1. Disconnect  the  battery and chock  the  road 
wheels for  safety.  
						

							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. 
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 band to 
one side  for assembly to back-plate. 
ASSEMBLE 
NOTE: 
If the  brake  linings  are oil-soaked  check 
prevent  the  plungers  falling out and  place  to and  if necessary renew  the output shaftoil 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.  Locking plate. 
24.  Retaining plate.  
25.  Packing  plate. 
26.  Fit the  rubber  dust  cover. 
Remove and overhaul  adjuster assembly 
16. Remove  the two  bolts  and  withdraw  the 
adjuster assembly  from 
the back-plate. 
17. Remove the plungers. 
18.  Screw  the adjuster  cone inwards 
to remove 
from  the  housing. 
discard  any unsatisfactory components. 
19. 
Clean 
the parts  in Girling  cleaning  fluid and  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. 
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. 
Assemble  adjuster assembly 
20. Grease and  screw in the  adjuster  cone. 
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. 
21. 
Grease and 
fit the  adjuster  plungers  and align  29. 
Fit new  pull-off 
springs  to relined  brake shoes  
						

							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 far or 
air 
will be  drawn  back into the system  around 
the  threads. 
4.  Smartly  depress  the foot  pedal,  pause and 
30. 
Fit the  brake  drum and secure  with the two then  allow  the pedal to rapidly  return, pause 
screws.  again 
before  repeating  the procedure. 
31. Connect  the expander  drawlink to the 5. Continue with the above  sequence  until all air 
actuating  lever with a new  clevis  pin, washer  bubbles cease whilst ensuring  that the 
and  split  pin.  reservoir 
is kept  topped
-up. 
32.  Turn 
the adjuster  cone fully 
in and tighten  the 6. Close the bleed  screw  immediately  after the 
two retaining  bolts left slack  in instruction 27. last  down  stroke,  whilst the pedal is 
33. Slacken off the adjuster two clicks  and firmly  depressed. 
apply  the hand  lever 
to centralise  the shoes. 
The  drum  should  then rotate  freely after 
releasing  the hand  lever. 
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. 
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  master 
cylinder  by gravity  for approximately  five 
minutes,  then bleed  as for  a primed  system.  
						

							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 
jump  hose at the  swivel  housing bracket. 
Cover  pipe 
to prevent  entry of dirt. 
7. The hub will require  tapping  with a mallet to 
finally release it from the  disc.  
						

							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 
530106 or a suitable  alternative  on the top 
swivel  and rest the stylus of the dial  indicator 
on  the  disc  face  near 
to the periphery.  The 
maximum  run out must  not exceed  0,151 mm.  
						

							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  seals from the 
inspect  the  outer  surfaces  for damage  and  master  cylinder  inlet 
ports the seals  are 
condition,  renew  the  complete assembly 
if different and should  be noted  for assembly, 
necessary.  discard both of the  seals. 
3. The  reservoir  is a  push  fit in the  master  7. 
Remove  the  retaining  ring  and O ring  seal 
cylinder  and  secured  by seals.  Carefully  ease  from  the machined outer  surface 
of the master 
the  reservoir  from  the master  cylinder  by  cylinder, discard both the seal  and retaining 
rolling 
it from  the  seals  as illustrated. 
ring. 
4. Using soft jaws, one either  side  of the  master 
cylinder  flange  and  clamp  the flange  in a 
suitable  vice.  Remove  the water  ingress  O 
ring  seal  from  the  master  cylinder 
to servo 
flange  and discard. 
5. Hold the outside  of the  transfer  housing with  a 
suitable  pair  of grips,  carefully  pull,  while 
working  the  pliers  in a  backwards  and 
forwards  rocking  motion 
to ease  the  housing 
off the  master  cylinder,  discard  the  housing 
and  vacuum  seal.