LAND ROVER DEFENDER 1996 Workshop Manual

70BRAKES
10
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.05
Service repair no - 70.55.16
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
Remove
1.Remove front road wheels.
2.Expose flexible brake hose by moving coiled
protective covering.
3.Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4.Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5.Remove split pin, retaining pins and springs,
withdraw pads. If refitting pads, identify them for
assembly to original locations.
6.Remove 2 bolts and withdraw caliper from swivel
housing.
WARNING: Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special toolLRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and withCAUTION, apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time, regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9.Finally remove pistons, identifying them with
their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.

BRAKES
11
REPAIR REV: 05/99 Assemble outboard pistons
13.Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15.Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16.Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17.Fit caliper, tighten bolts evenly to
82 Nm (60
lbf/ft).
18.Connect brake flexible hoses to caliper. Tighten
to
15 Nm (11 lbf/ft).
19.Remove hose clamps.
20.Insert pads. Fit pins and springs, secure using
new split pin.
21.Bleed brake system
See Brake System Bleed
.
22.Press brake pedal firmly several times to locate
friction pads.
23.Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
24.Road test vehicle. Note that new friction pads
require 'bedding-in', this may take several
hundred miles before brakes are at maximum
efficiency.FRONT BRAKE DISCS
Service repair no - 70.10.10.
Remove
1.Remove hub assembly
See FRONT AXLE AND
FINAL DRIVE, Repair, Front hub assembly
.
2.Remove 5 hub to disc bolts.
3.Tap disc to separate from hub.
NOTE: On 110/130 vehicles ventilated
discs are fitted as standard.
Refit
4.Locate disc to hub.
5.Apply Loctite 270 to disc bolts and tighten to
73
Nm (54 lbf/ft).
6.Check total disc runout with a dial indicator, this
must not exceed 0,15 mm, 0.006 in. If necessary
reposition disc.
7.Fit hub assembly
See FRONT AXLE AND
FINAL DRIVE, Repair, Front hub assembly
.
Disc reclamation
8.Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm (0.47
in.) - solid discs, 22 mm (0.90 in) - ventilated
discs. Machine equal amount off each face.
NOTE: The disc MUST BE renewed if the
minimum running thickness stamped on
the disc is recorded.

70BRAKES
12
REPAIR REAR BRAKE CALIPER ASSEMBLY
Key to rear caliper
1.Caliper
2.Bleed screw
3.Pad retaining springs
4.Brake pads
5.Piston6.Wiper seal retainer
7.Wiper seal
8.Fluid seal
9.Retaining pins

BRAKES
13
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Before starting repair refer to General brake service
practice
See General Brake Service Practice.
Remove caliper
1.Remove rear road wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
90 Models
110/130 Models
3.Remove brake pipe from rear brake caliper.4.Seal pipe ends to prevent ingress of dirt.
5.Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6.Remove 2 bolts and withdraw caliper from rear
axle.
Repair
WARNING: Do not separate caliper halves.
7.Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTIONexpel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9.Finally, remove pistons keeping them identified
with their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.
13.Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.

70BRAKES
14
REPAIRREV: 05/99 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 2 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
or fit new split pins, depending on vehicle model.
Note correct position of retaining springs on 90
models.
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. Finally
tighten road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
25.Road test vehicle. Note 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 disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm (54 lbf/ft).
6.Check total disc run out, this must not exceed
0,15 mm (0.006 in). If necessary reposition disc.
7.Fit rear hub assembly
See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly
.
Disc reclamation
8.Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm.
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.Aadjuster 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
REPAIRREV: 05/99 TRANSMISSION BRAKE SHOES
Service repair no - 70.45.18
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. 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, see J6337.
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. If new brake shoes are to be fitted, the
srings 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 hand 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/ft)to
ensure brake drum is locked.
18.Slacken off adjuster bolt by 1.5 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
handbrake.

BRAKES
17
REPAIR HANDBRAKE 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.
2.Remove 3 trim studs and lift up handbrake
gaiter.
3.Remove split pin, clevis pin, washer and
disconnect cable from handbrake 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 handbrake 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 handbrake lever and secure with
clevis pin and split pin.
12.Fit handbrake gaiter.
13.Fit brake drum. Tighten screw to
25 Nm (18
lbf/ft).
14.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
15.Tighten adjuster bolt further to
25 Nm (18 lbf/ft)
to ensure brake drum is locked.
16.Slacken off adjuster bolt by 1.5 turns to give
brake shoes running clearance. Check that the
drum is free to rotate.
17.Slacken locknut and adjust cable to give the
handbrake pawl two notches free movement on
the rachet before being fully operational on third
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.
18.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm (34 lbf/ft).
19.Remove wheel chocks and check operation of
handbrake.

70BRAKES
18
REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery.
2.Remove air cleaner
See FUEL SYSTEM,
Repair, Air cleaner
.
3.Detach servo hose from vacuum pump.
4.Remove bolt securing air cleaner support
bracket strut.
5.Remove 6 bolts securing vacuum pump.
6.Detach pump complete with strut and harness
bracket. Note location of strut and bracket for
Refit.
Refit
7.Clean mating faces of pump and block.
8.Loosely assemble pump to block with a new
gasket and with air cleaner strut and harness
bracket located under heads of bolts noted
during Remove.
9.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm (18 lbf/ft).
10.Secure strut to air cleaner bracket.
11.Connect vacuum hose and secure with clip.
12.Refit air cleaner
See FUEL SYSTEM, Repair,
Air cleaner
.

BRAKES
1
OVERHAUL REV: 05/99
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
14.Swirl tube
15.Master cylinder body
16.Reservoir seals
17.Reservoir
18.Low fluid level switch and cap