Land Rover Defender Workshop Rover Manual
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BRAKES5 REPAIR SERVO ASSEMBLY Service repairno-70.50.01 Remove Before starting repairrefertogeneral brakeservice practice See General BrakeService Practice. NOTE:Thenon-return valveandgrommet, are theonly serviceable components. In event offailure ordamage, fitanew unit. 1.Remove mastercylinderSeeMaster cylinder. 2. Disconnect vacuumsupplyhosefromservo unit. 3. Atfootwell, release2brake pedalreturn springs. 4. Disconnect leadsfrombrake lightswitch atrear of pedal box. 5. Remove blankinggrommets fromeach sideof pedal box. 6. Remove splitpinand clevis pinsecuring servo push rodtobrake pedal. 7. Remove 4nuts andplain washers securing servo topedal box. 8. Remove servoassembly andrubber washer from bulkhead. Refit 9. Locate servoassembly andrubber washer to engine bulkhead andsecure topedal box. Tighten fixingsto 14Nm (10lbf/ft). 10. Fitbrake pedaltoservo pushrodwith clevis pin and new splitpin. 11. Fitblanking grommets toeach sideofpedal box. 12. Atfootwell, attachpedalreturn springs. 13. Connect vacuumhosetoservo non-return valve. 14. Fitbrake master cylinder toservo unit See Master cylinder .
70BRAKES 6 REPAIR BRAKE PEDAL Service repairno-70.35.01 -Brake pedal Service repairno-70.35.03 -Pedal box Remove 1. Remove brakeservoassembly. SeeServo assembly . 2. Remove 6bolts securing pedalboxtoengine bulkhead. 3. Taking carenotdamage brakefluidpipes, remove pedalboxassembly andgasket. 4. Release returnsprings frompedal andpedal box bosses. 5. Using asuitable punch,driftoutretaining pinand withdraw pedalpivotshaft. 6. Remove brakepedalcomplete withpivot bushes. 7. Examine components forwear ordamage, renew asnecessary. 8. Ifitis necessary tofitnew pivot bushes, they must bereamed outto15,87 mm±0,02 mm (0.625 ±0.001 in)after fitment. Refit 9. Lubricate pedalpivotshaft andbushes with general purpose grease. 10. Fitpedal topedal box,insert pivotshaft and secure withnew splitpin. 11. Attach returnsprings topedal andpedal box bosses. 12. Fitpedal boxand gasket toengine bulkhead. Tighten fixingsto 25Nm (18lbf/ft). 13. Fitbrake servoassembly.SeeServo assembly .
BRAKES7 REPAIR REV: 09/97 FRONT BRAKE PADS-ALL MODELS Service repairno-70.40.02 Remove 1. Remove frontroad wheels . 2. Clean exterior ofcalipers. 3. Remove splitpinfrom retaining pins. 4. Remove padretaining pinsandanti-rattle springs. 5. Remove brakepads. 6. Clean exposed partsofpistons, usingnewbrake fluid. Wipe away excess withalint free cloth. 7. Using piston clampLRT-70-500 presseach piston backintoitsbore. Ensure thatdisplaced brake fluiddoes notoverflow fromreservoir. Refit 8. Fitbrake pads. 9. Fitpad retaining pinsandanti-rattle springs. Secure withnew splitpins. 10. Apply service brakepedalseveral timestolocate pads. 11. Fitroad wheels. Tightenwheelnutstocorrect torque: Alloy wheels - 130Nm(96lbf/ft) Steel wheels -100Nm(80lbf/ft) Heavy dutywheels -170Nm(125 lbf/ft) 12.Check fluidreservoir. Topupifnecessary, using correct gradeoffluid See LUBRICANTS, FLUIDS ANDCAPACITIES, Information, Recommended lubricantsandfluids .
70BRAKES 8 REPAIR REV:09/97 REAR BRAKE PADS Service repairno-70.40.03 Service tool: Remove 1. Remove rearroad wheels. 2. Clean exterior ofcalipers. 3. Remove padretaining pinsandanti-rattle springs. Notedifferences between90and 110/130 models. 4. Remove brakepads. 5. Clean exposed partsofpistons, usingnewbrake fluid. Wipe away excess withalint free cloth. 6. Using piston clampLRT-70-500 presseach piston backintoitsbore. Ensure thatdisplaced brake fluiddoes notoverflow fromreservoir. Refit 7. Insert brake pads. 8. Fitanti-rattle springsandsecure withretaining pins. 9. Apply service brakepedalseveral timestolocate pads. 10. Fitroad wheels, removechassis standsand jack. Tighten wheelnutstocorrect torque: Alloy wheels - 130Nm(96lbf/ft) Steel wheels -100Nm(80lbf/ft) Heavy dutywheels -170Nm(125 lbf/ft) 11.Check fluidreservoir, topupifnecessary, using correct gradeoffluid See LUBRICANTS, FLUIDS ANDCAPACITIES, Information, Recommended lubricantsandfluids . 90Models 110/130 Models
BRAKES9 REPAIR FRONT BRAKE CALIPER ASSEMBLY Keytocaliper 1. Caliper 2. Bleedscrew 3. Anti-rattle springs 4. Pad retaining pins 5. Split pin 6. Friction pads 7. Piston 8. Wiper sealretainer 9. Wiper seal 10. Fluid seal 11. Brake disc
70BRAKES 10 REPAIR FRONT BRAKE CALIPERS Service repairno-70.55.05 Service repairno-70.55.16 Before starting repairrefertogeneral brakeservice practice See General BrakeService Practice. Remove 1. Remove frontroad wheels. 2.Expose flexiblebrakehosebymoving coiled protective covering. 3. Using arecognised hoseclamp, clamphoseto prevent lossofbrake fluid. 4. Disconnect rigidbrake pipefrom flexible hose, seal exposed endstoprevent ingressofdirt. 5. Remove splitpin,retaining pinsandsprings, withdraw pads.Ifrefitting pads,identify themfor assembly tooriginal locations. 6. Remove 2bolts andwithdraw caliperfromswivel housing. WARNING: Donot separate caliperhalves 7. Clean outersurfaces ofcaliper usingaerosol brake cleaner. 8.Using special toolLRT-70-500 ,clamp pistons in inboard halfofcaliper. Gently,keeping fingers clear, andwith CAUTION ,apply airpressure to fluid inletporttoexpel pistons. Itis unlikely that pistons willexpel atsame time,regulate rate with asuitable pieceofwood between appropriate pistonandcaliper. 9. Finally remove pistons, identifying themwith their respective bores. 10. Remove wipersealretainer byinserting ablunt screwdriver betweenretainerandseal. Pry retainer carefully frommouth ofbore. 11. Taking carenottodamage sealgrooves, extract wiper sealandfluid seal. 12. Clean bores, pistons andseal grooves using clean brake fluidonly. Ifcaliper orpistons are corroded, ortheir condition isnot perfect, new parts mustbefitted.
BRAKES11 REPAIR REV: 09/97 Assemble outboardpistons 13. Coat newfluidseal withbrake fluid.Ease seal into groove inbore using onlyfingers, ensuring it is properly seated.Fluidsealandgroove arenot same insection, sowhen sealisseated itfeels raised totouch atedge furthest awayfrom mouth ofbore. 14. Coat appropriate pistonwithbrake fluid.Insert it squarely intobore byhand only.Donot tiltpiston during insertion, leaveapproximately 8mm projecting frombore. 15. Coat newwiper sealwithbrake fluidandfitto new sealretainer. Slideassembly, sealfirst, over protruding pistonandintobore recess. Use piston clamptopress home sealretainer and piston. Mounting inboardpistons 16. Clamp outboard pistonsandcarry outsame procedure forremoving andfitting outboard pistons andseals, instructions 8to 15. Fit calipers andpads 17. Fitcaliper, tightenboltsevenly to 82Nm (60 lbf/ft). 18. Connect brakeflexible hosestocaliper. Tighten to 15 Nm (11lbf/ft). 19. Remove hoseclamps. 20. Insert pads.Fitpins andsprings, secureusing new splitpin. 21. Bleed brakesystem SeeBrake System Bleed . 22. Press brakepedalfirmlyseveral timestolocate friction pads. 23. Fitroad wheels, removeaxlestands. Finally tighten roadwheel nutstocorrect torque: Alloy wheels - 130Nm(96lbf/ft) Steel wheels -100Nm(80lbf/ft) Heavy dutywheels -170Nm(125 lbf/ft) 24.Road testvehicle. Notethatnew friction pads require bedding-in, thismay takeseveral hundred milesbefore brakes areatmaximum efficiency. FRONT BRAKE DISCS Service repairno-70.10.10. Remove 1. Remove hubassembly See FRONT AXLEAND FINAL DRIVE, Repair, Fronthubassembly . 2.Remove 5hub todisc bolts. 3. Tap disc toseparate fromhub. NOTE: On110/130 vehicles ventilated discs arefitted asstandard. Refit 4. Locate disctohub. 5. Apply Loctite 270todisc bolts andtighten to 73 Nm (54lbf/ft). 6.Check totaldiscrunout withadial indicator, this must notexceed 0,15mm,0.006 in.Ifnecessary reposition disc. 7. Fithub assembly See FRONT AXLEAND FINAL DRIVE, Repair, Fronthubassembly . Disc reclamation 8. Check discthickness. Thisdimension maybe machined tominimum thickness of12 mm (0.47 in.) -solid discs, 22mm (0.90 in)-ventilated discs. Machine equalamount offeach face. NOTE: Thedisc MUST BErenewed ifthe minimum runningthickness stampedon the disc isrecorded.
70BRAKES 12 REPAIR REAR BRAKE CALIPER ASSEMBLY Keytorear caliper 1. Caliper 2. Bleed screw 3. Pad retaining springs 4. Brake pads 5. Piston 6. Wiper sealretainer 7. Wiper seal 8. Fluid seal 9. Retaining pins
BRAKES13 REPAIR REAR BRAKE CALIPERS Service repairno-70.55.06 Service repairno-70.55.17 Before starting repairrefertoGeneral brakeservice practice See General BrakeService Practice. Remove caliper 1. Remove rearroad wheels. 2. Using arecognised hoseclamp, clampflexible brake hoseabove rearaxle. 90Models 110/130 Models 3. Remove brakepipefrom rearbrake caliper. 4. Seal pipeends toprevent ingressofdirt. 5. Remove retaining pinsandsprings andwithdraw pads. Ifsame padsaretobe refitted, identify them forassembly inoriginal positions. 6. Remove 2bolts andwithdraw caliperfromrear axle. Repair WARNING: Donot separate caliperhalves. 7. Clean outersurfaces ofcaliper withaerosol brake cleaner. 8.WITH CAUTION expelpistons fromtheirbores by applying airpressure tofluid inletport. Itis unlikely bothpistons willexpel atsame time, regulate ratewith asuitable pieceofwood inserted between twopistons. 9. Finally, remove pistonskeeping themidentified with their respective bores. 10. Remove wipersealretainer byinserting ablunt screwdriver betweenretainerandseal andpry retainer carefully frommouth ofbore. 11. Taking carenottodamage sealgrooves, extract wiper sealandfluid seal. 12. Clean bores, pistons andparticularly seal grooves usingcleanbrake fluidonly. Ifcaliper or pistons arecorroded ortheir condition isnot perfect newparts mustbefitted. 13. Apply brakefluidtonew seal. Fitseal into groove inbore. When sealisseated itfeels raised totouch atedge furthest awayfrom mouth ofbore. 14. Coat piston withbrake fluid.Insert itsquarely into bore. Donot tiltpiston during insertion and leave 8mmprojecting frombore.
70BRAKES 14 REPAIR REV:09/97 15. Coat anew wiper sealwithbrake fluidandfitto new sealretainer. Slideassembly, sealfirst, over protruding pistonintobore recess. 16. Using special toolLRT-70-500 -piston clamp, press home sealretainer andpiston. Mounting inboardpiston 17. Carry outsame procedure asfor removing and fitting outboard pistonandseals, instructions 8to 16. Fit calipers andpads tovehicle 18. Fitcaliper toaxle, tighten 2bolts evenly to 82 Nm (60lbf/ft). 19. Connect brakepipetocaliper. Tighten to15Nm (11 lbf/ft). 20. Remove clampfromflexible brakehose. 21.Insert padsandretaining springs,securein position withnew retaining pinsandspread ends or fitnew splitpins, depending onvehicle model. Note correct position ofretaining springson90 models. 22. Bleed brakesystem SeeBrake System Bleed. 23. Press brakepedalfirmlyseveral timestolocate pads. 24. Fitroad wheels, removeaxlestands. Finally tighten roadwheel nutstocorrect torque: Alloy wheels - 130Nm(96lbf/ft) Steel wheels -100Nm(80lbf/ft) Heavy dutywheels -170Nm(125 lbf/ft) 25.Road testvehicle. Notenewbrake padsrequire bedding-in, forseveral hundred milesbefore brakes areatmaximum efficiency. REAR BRAKE DISC Service repairno-70.10.11. Remove 1. Remove rearhubassembly See REAR AXLE AND FINAL DRIVE, Repair, Rearhub assembly . 2. Remove discbolts. 3. Remove discfrom rearhub. Refit 4. Fitdisc torear hub. 5. Fitdisc bolts. Tighten to 73Nm (54lbf/ft). 6.Check totaldiscrunout, thismust notexceed 0,15 mm(0.006 in).Ifnecessary repositiondisc. 7. Fitrear hubassembly See REAR AXLEAND FINAL DRIVE, Repair, RearHubAssembly . Disc reclamation 8. Check discthickness. Thisdimension maybe machined tominimum thickness of12 mm. Machine equalamounts offeach face. NOTE: Thebrake discMUST BErenewed if the minimum runningthickness stamped on the disc isrecorded.