brake LAND ROVER DEFENDER 1999 Manual Online

BRAKES
1
ADJUSTMENT BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.See this Section. general brake
service practice
During bleed procedure, brake fluid level must
not be allowed to fall below the MIN mark. Keep
reservoir topped up to the MAX mark.
To bleed the hydraulic circuits, four bleed
nipples are provided, one at each caliper.
There are two methods by which air can be removed
from the braking system:-
1.MANUAL BLEED PROCEDURE
2.PRESSURE BLEED PROCEDURE
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lb/in.
Manual bleed procedure
Equipment required
Clean glass receptacle
Bleed hose
Wrench
Approx. 2 litres (3 pts) brake fluid
Master cylinder bleed
1.Disconnect battery negative lead.
2.Depress brake pedal fully and slowly 5 times.
3.Release pedal and wait 10 seconds.
4.Repeat until firm resistance is felt at the pedal.Complete circuit bleed
1.Disconnect battery negative lead.
2.Fit bleed hose to caliper bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed nipple.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depresses, tighten bleed
nipple then release pedal.
7.Repeat procedure for remaining calipers.
8.Fit bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete.
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70BRAKES
2
ADJUSTMENT PARK BRAKE - ADJUST
Service repair no - 70.45.09
Check
NOTE: The park brake should be fully
operational on third notch of ratchet.
1.Raise one rear wheel clear of ground and
support on axle stand.
2.Release park brake lever.
3.Tighten brake adjuster to25 Nm (18 lbf.ft)to
fully expand shoes to drum.
4.Back off adjuster 1
1/2turns, check that drum is
free to rotate.
5.Check operation of park brake lever to give pawl
2 notches free movement on ratchet before
being fully operational on third notch of ratchet.
Adjust park brake accordingly if lever travel
exceeds the above tolerance.
CAUTION: 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.
6.Remove axle stand and wheel chock.
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BRAKES
1
REPAIR ECU - ABS
Service repair no - 70.65.01
Remove
1.Disconnect battery negative lead.
2.Release and remove passenger seat base.
3.Release clip securing ECU cover plate.
4.Remove ECU cover plate.
5.Disconnect 3 multiplugs from ABS ECU.
6.Disconnect 2 multiplugs from engine
management ECU.
7.Release seat base carpet to gain access to ECU
mounting plate Torx screws.
8.Remove 2 Torx screws securing front edge of
ECU mounting plate.
9.Remove nut securing rear edge of ECU
mounting plate.
10.Remove mounting plate and ECU assembly from
seat base.
11.Remove 3 bolts securing ABS ECU to mounting
plate.
12.Remove ABS ECU.
Refit
13.Position ABS ECU to mounting plate and secure
with bolts.
14.Fit mounting plate and ECU assembly to seat
base.
15.Fit Torx screws and nut securing mounting plate
to seat base.
16.Re-position carpet.
17.Connect multiplugs to ABS and engine
management ECU’s.
18.Fit ECU cover plate to seat base and secure in
position with clip.
19.Fit passenger seat base.
20.Reconnect battery negative lead.
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70BRAKES
2
REPAIR SENSOR - ABS - FRONT WHEEL
Service repair no - 70.65.30
Remove
1.Raise vehicle on a 2 post ramp.
2.Carefully prize ABS sensor from front hub.
3.Release clip securing ABS sensor harness to
brake pipe.
4.Release clip securing ABS sensor harness to
inner wing.
5.Lower vehicle.
6.Release second clip securing ABS harness to
inner wing.
7.Disconnect sensor harness multiplug.
8.Remove sensor and harness.
Refit
9.Connect sensor harness multiplug.
10.Position sensor harness and secure to inner
wing with clip.
11.Raise vehicle.
12.Secure harness to inner wing and brake pipe
with clips.
13.Apply grease to sensor.
14.Carefully fit sensor to hub assembly.
15.Lower vehicle.
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BRAKES
3
REPAIR SENSORS - ABS - REAR WHEELS
Service repair no - 70.65.31
Remove
1.Raise vehicle on a 2 post ramp.
2.Remove both rear wheels.
3.Remove 3 bolts securing each brake disc
backplate to hub assemblies.
4.Remove both back plates.
5.Remove 2 cable ties securing sensor harness to
outer ends of axle.
6.Carefully prise both sensors from hub
assemblies.
7.Release 4 clips securing sensor harness to axle.
8.Release cable tie securing harness to
differential.
9.Release 3 cable ties securing harness to chassis
longitudinal.
10.Disconnect sensor multiplug.
11.Remove harness and sensor assembly.
Refit
12.Position harness and sensor assembly to vehicle
and connect multiplug.
13.Apply grease to both sensors.
14.Carefully fit both sensors to hub assemblies.
15.Secure harness to axle and differential with
cable ties.
16.Secure harness to axle with clips.
17.Secure harness to chassis with cable ties.
18.Fit both back plates to hub assemblies and
secure with bolts.
19.Fit rear wheels and tighten to130 Nm (95 lbf.ft)
.
20.Lower vehicle.
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70BRAKES
4
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Remove
1.Disconnect battery negative lead.
2.Place a container under the master cylinder to
collect any brake fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
3.Clean area around master cylinder ports.
4.Loosen 2 unions securing brake pipes to master
cylinder ports.
5.Disconnect both brake pipes from master
cylinder. Cover, not plug, pipe ends to prevent
entry of dirt.
6.Disconnect 2 Lucars from reservoir cap.
7.Remove 2 nuts securing master cylinder to
brake servo.
8.Withdraw master cylinder from servo and
remove.
Do not carry out further dismantling if
component is removed for access only.9.Carefully ease reservoir from master cylinder by
rolling it from seals.
10.Remove seals from master cylinder.
NOTE: Master cylinder to reservoir seals
are different sizes.
11.Fit NEW seals to master cylinder, ensuring seals
are fitted to correct ports.
12.Fit reservoir to master cylinder.
Refit
13.Ensuring that water ingress seal is in position, fit
master cylinder to servo.
14.Fit nuts securing master cylinder to servo and
tighten to26 Nm (19 lbf.ft).
15.Connect brake pipes to master cylinder and
tighten unions to15 Nm (11 lbf.ft).
16.Connect Lucars to reservoir cap.
17.Fill reservoir with recommended brake fluid.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
18.Bleed the brake system.See Adjustment.
19.Reconnect battery negative lead.
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BRAKES
5
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting, refer to general brake service
practice.See Adjustment.
NOTE: The non-return valve and grommet
are the only serviceable components. In
event of failure or damage, fit a new unit.
1.Remove master cylinder.See this Section.
2.Release vacuum hose from servo.
3.Disconnect brake light switch Lucars.
4.Remove 3 screws securing closing panel to
lower’A’post.
5.Release closing panel sufficient to gain access
to brake pedal return springs.
6.Release 2 brake pedal return springs from brake
pedal.
7.Remove blanking grommets from either side of
pedal box.
8.Remove split pin and clevis pin securing servo
push rod to brake pedal.
9.Remove 2 nuts securing servo to pedal box.
10.Remove servo assembly and rubber washer
from pedal box.
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70BRAKES
6
REPAIR Refit
11.Fit rubber washer and servo assembly to pedal
box.
12.Fit nuts securing servo to pedal box and tighten
to14 Nm. (10 lbf.ft)
13.Position brake pedal to servo push rod.
14.Fit clevis pin and NEW split pin to secure brake
pedal to servo push rod.
15.Fit blanking grommets to each side of pedal box.
16.Attach pedal return springs to brake pedal.
17.Position closing panel and tighten screws to
lower’A’post.
18.Connect vacuum hose to servo.
19.Connect brake switch Lucars.
20.Fit brake master cylinder.See this Section.MODULATOR UNIT - ABS
Service repair no - 70.65.49
Remove
1.Position cloth under modulator to absorb any
fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
2.Disconnect 2 inlet brake pipe unions from pump
side of modulator.
3.Disconnect 4 outlet brake pipe unions from top
of modulator.
CAUTION: Plug the connections.
4.Disconnect 2 multiplugs from rear of modulator.
5.Loosen nut securing rear of modulator to
mounting bracket.
6.Remove 2 nuts securing front of modulator to
mounting bracket.
7.Release modulator from mounting bracket.
8.Disconnect multiplug from base of modulator.
9.Remove modulator.
Do not carry out further dismantling if
component is removed for access only.
10.Remove 3 mounting rubbers from old modulator
and fit to new.
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BRAKES
7
REPAIR Refit
11.Position modulator to mounting bracket and
connect multiplug.
12.Fit modulator to mounting bracket and tighten
nuts to9 Nm (7 lbf.ft).
13.Connect 2 multiplugs to rear of modulator.
14.Remove plugs from brake pipes and modulator.
15.Clean brake pipe unions.
16.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
17.Tighten all unions to14 Nm (10 lbf.ft).
18.Bleed brake system.See Adjustment.
NOTE: To ensure correct operation, the
ABS system MUST be tested using
TestBook.BRAKE CALIPER - FRONT
Service repair no - 70.55.02
Remove
1.Loosen front road wheel nuts.
2.Raise front of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from pad retaining pins.
5.Remove brake pad retainers and springs.
6.Remove brake pads and shim if fitted.
7.Pull back brake hose shield.
8.Clamp brake hose using a suitable clamp.
9.Position container beneath brake caliper to
collect spillage.
10.Loosen brake pipe union and disconnect from
caliper.
11.Plug brake pipe and caliper connections.
12.Remove 2 bolts securing caliper.
13.Remove brake caliper.
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70BRAKES
8
REPAIR Refit
14.Clean caliper to hub mating faces.
15.Position caliper to hub, fit bolts and tighten to82
Nm (60 lbf.ft).
16.Remove plugs from pipe to caliper connections
and wipe.
17.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
18.Apply a light film of grease to rear of brake pads.
19.Fit pads to calipers.
From 02MY, ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
20.Fit pad retainers and springs.
21.Fit split pins to retainers.
22.Remove brake hose clamp.
23.Bleed brakes.See Adjustment.
24.Depress brake pedal to seat pads onto discs.
25.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).BRAKE CALIPER - REAR
Service repair no - 70.55.03
Remove
1.Loosen rear road wheel nuts.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from brake pad retaining pins.
5.Remove brake pad retaining pins.
6.Remove brake pad retainer springs.
7.Remove brake pads and shim if fitted.
8.Position container beneath brake caliper to
collect spillage.
9.Loosen brake pipe union and disconnect from
caliper.
CAUTION: Plug the connections.
10.Remove 2 bolts securing caliper.
11.Remove brake caliper.
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