handbrake LAND ROVER DEFENDER 1996 Workshop Manual

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required
instructions are given for carrying out the service
procedure, or a cross reference is given to the section
in the manual where the procedure may be found.
Service Maintenance Schedules are published
separately to reflect the needs and intervals for each
vehicle variant. Procedures in the Workshop Manual
must be used in conjunction with the Service
Schedule sheets.
Service Maintenance Schedules are available from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seat belts, seat belt
mountings, seat belt buckles and operation of inertia
seat belts.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear wipers and washers and
condition of wiper blades.CHECK OPERATION OF HANDBRAKE
Handbrake check/adjust
1.Chock road wheels.
2.Raise one rear wheel clear of ground and
support securely with axle stand.
3.Release handbrake lever.
4.Underneath vehicle, tighten adjuster bolt
clockwise to
25 Nm (18 lbf/ft)to fully lock brake
drum.
5.Slacken adjusting bolt by 1.5 turns to give brake
shoes running clearance. Check that the drum is
free to rotate.
6.Adjust handbrake cable locknuts to give pawl
two notches free movement on the rachet before
being fully operational on third notch of rachet.
NOTE: Cable adjustment must ONLY be
used for initial setting and to compensate
for cable stretch. It MUST NOT be used to
take up brake shoe wear, which MUST be adjusted
at brake drum.
7.Operate handbrake to settle brake shoes.
Recheck handbrake is fully operational on third
notch of rachet pawl. Readjust if necessary.
8.Remove axle stand and wheel chocks.

MAINTENANCE
13
MAINTENANCE REV: 05/992.When pure diesel is emitted, retighten drain
plug.
3.Disconnect fuel inlet pipe at sedimenter. Raise
and support pipe above level of fuel tank to
prevent fuel draining from tank.
4.Support sedimenter bowl, unscrew bolt and
remove bowl.
5.Remove sedimenter element.
6.Clean all components in kerosene.
7.Fit new seals.
8.Fit element into sedimenter bowl.
9.Secure bowl to sedimenter head.
10.Fit fuel inlet pipe to sedimenter.
11.Slacken drain plug and when pure diesel is
emitted, retighten plug.
12.If necessary, prime the system.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK SECURITY OF TOWING BRACKET
FITTINGSCARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests MUST
NOT be carried out.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
testing
Check the following components:
1.Engine for excessive noise.
2.Clutch for slip, judder or spin/drag.
3.Gear selection/noise - high/low range.
4.Steering for abnormal noise/effort.
5.Steering for free play.
6.All instruments, gauges and warning indicators.
7.Heater and air conditioning systems.
8.Heated rear screen.
9.Shock absorbers - ride irregularities.
10.Foot brake, on emergency stop, pulling to one
side, binding and pedal effort.
11.Handbrake operation.
12.Seat reclining and latching.
13.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
14.Road wheel balance.
15.Transmissions for vibrations.
16.Body noises, squeaks and rattles.
17.Excessive exhaust smoke.
18.Engine idle speed.
19.Endorse service record.
20.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

37MANUAL GEARBOX
2
ADJUSTMENT FIFTH GEAR STOP SCREW - ADJUST
Service repair no - 37.16.67
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Remove tunnel carpet.
7.Remove retaining screws and release fuse box
cover.
8.Remove 2 screws and release fuse box from
bulkhead to assist next operation.
9.Remove 16 screws securing tunnel cover to
vehicle body.
10.Manouvre tunnel cover to clear handbrake lever
and remove from vehicle.
11.Fit gear lever and knob and select reverse gear.

37MANUAL GEARBOX
2
REPAIR
10.Remove 3 trim studs and lift up handbrake
gaiter.
11.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
12.Drain cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
13.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
14.Slacken retaining clip and disconnect radiator
top hose at thermostat housing.
15.Slacken retaining clip and disconnect intake
hose at induction manifold. If EGR system is
fitted, slacken 2 retaining clips and disconnect
intake hose at intercooler.
16.Slacken retaining clip and disconnect hose at
turbocharger.
17.Remove bolt securing transmission breather
pipe clip to rear of engine.
18.Release breather pipes.
19.Release ties securing gearbox harness to
breather pipes.
20.Raise vehicle on ramp.
21.Position a suitable container under transmission
and drain main gearbox and transfer box
See
MAINTENANCE , Under vehicle maintenance
.
22.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
23.Remove 4 nuts and disconnect propeller shaft
from transfer box.

37MANUAL GEARBOX
4
REPAIR
37.Pull handbrake cable through heel board and tie
aside.
38.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.Release speedometer cable from retaining clip
on transfer box.
40.Remove retaining nut and release battery earth
strap from transfer box.
41.Secure manufactured cradleLRT-99-007to a
suitable hydraulic hoist.
42.Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44.Disconnect differential lock switch and reverse
light connectors.
45.Remove bolt and release earth leads from RH
side of transfer box.
46.Support engine under sump with a jack.
47.Remove 14 bell housing to engine fixings.
48.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49.Lower hoist and remove gearbox assembly.

37MANUAL GEARBOX
6
REPAIRREV: 05/99 78.Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
80.Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90
orSee MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe
.
82.Fit rear propeller shaft to transmission brake
drum. Tighten nuts to
47 Nm (33 lbf/ft).
83.Remove 3 bolts securing support cradle to
transmission and remove hoist.
84.Reconnect battery earth strap to transfer box
fixing.
85.Connect speedometer cable to transfer box and
secure with retaining clip.
86.Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87.Locate backing plate on slave cylinder.
88.Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to
25 Nm
(18 lbf/ft).
89.Fit front propeller shaft to transfer box. Tighten
nuts to
47 Nm (33 lbf/ft).
90.Refill main gearbox and transfer boxSee
MAINTENANCE , Under vehicle maintenance
.
91.Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92.Lower vehicle on ramp.
93.Fit ties to secure gearbox harness to
transmission breather pipes.
94.Fit breather pipe retaining clip to rear of engine.
95.Reconnect charge air hose at turbocharger.
96.Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97.Reconnect radiator top hose at thermostat
housing.
98.Fit viscous fan unit
See COOLING SYSTEM,
Repair, Viscous coupling and fan
.
99.Reconnect battery.100.Refill cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
101.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102.Locate insulation pad over gear levers and fit to
tunnel cover.
103.Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104.Fit gear lever cover.
105.Fit gear lever and transfer box lever knobs.
106.Fit gearbox cover carpet.
107.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Under
vehicle maintenance
.

41TRANSFER GEARBOX
2
REPAIR
11.Remove 3 trim studs and lift up handbrake
gaiter.
12.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
13.Release handbrake outer cable from heelboard.
14.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl
.
15.Raise vehicle on ramp.
16.Drain transfer box oil
See SECTION 10,
Maintenance, Under vehicle maintenance
.
17.Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90
orSee MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
.
18.Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
19.Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
20.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
21.Remove 4 nuts, disconnect propeller shaft from
transfer box, and tie aside.
22.Remove retaining clip at lower end of pivot arm
and disconnect differential lock control operating
rod.

TRANSFER GEARBOX
5
REPAIR REV: 05/9963.Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64.Lower vehicle ramp.
65.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66.Connect high/low lever to operating rod.
67.Fit breather pipe banjo union to high/low
cross-shaft housing.
68.Fit centre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69.If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70.Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
.
71.Reconnect battery.
72.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Handbrake
cable
.

70BRAKES
2
DESCRIPTION AND OPERATION REV: 05/99 OPERATION
Master cylinder
A tandem master cylinder, which is assisted by a light
weight, short, compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank.
When the footbrake is applied, the primary plunger
assembly moves up the cylinder bore and the
pressure created acts in conjunction with the primary
spring to overcome the secondary springs, thus
moving the secondary plunger assembly up the bore.
At the same time initial movement of both plungers
takes the recuperating seals past the cut-off holes in
the cylinder chambers 'A' and 'C',see J6321, and
applies pressure to the fliud in those chambers, which
is directed to the respective circuits.
The fluid in chambers 'B' and 'D'is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers 'A' and
'C'and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers 'B' and 'D'to flow through the holes
in the plungers, over the collapsed seals and into
chambers 'A' and 'C'respectively. The movement of
fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers 'A' and 'C'to move through the cut off holes
into the fluid reservoir.The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied. Power
is obtained from a vacuum pump located on the RH
side of the engine cylinder block. The vacuum is
applied to both sides of a flexing diaphragm, and by
admitting atmosheric pressure to the rear diaphragm,
assistance is obtained. The servo unit is mounted
between the brake pedal and master cylinder and is
linked to these by push rods. Should a vacuum failure
occur, the two push rods will act as a single rod
allowing the brakes to function in the normal way,
although more effort will be required to operate the
brake pedal.
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate as a bulb
check when the ignition is switched on and
extinguishes when the engine is running and the
handbrake is released. A hydraulic failure in the
system will result in fluid loss, causing the warning
light to illuminate.
On 90 models a pressure reducing valve (PRV), fitted
to the RH bulkhead in the engine compartment,
maintains the braking balance, see J6322. Pressure
to the rear calipers is regulated by the PRV, this valve
is of the failure by-pass type, allowing full system
pressure to the rear brake calipers in the event of a
front (secondary) circuit failure.
NOTE: In some countries, a pressure
reducing valve may be fitted to 110 models
to conform to legal requirements.

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.