handbrake LAND ROVER DISCOVERY 1999 Owner's Manual

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-28 REPAIRS
15.Remove handbrake drum retaining screw and
remove brake drum.
16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
18. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
19. If fitted Remove and discard clevis pin
securing differential lock selector cable to
transfer gearbox.20. If fitted Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
21. If fitted Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
22.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and remove outer cable from abutment
bracket.
23. Up to 03 Model Year - If fitted: Disconnect
from differential lock warning lamp switch and
multiplugs from high/low ratio switch and
neutral sensor.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
40.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit but do not tighten six bolts securing gearbox
housing to engine.
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect multiplug to inhibitor switch.
7. If fitted: Connect and adjust differential lock
selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
8.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
9.Position selector cable to gearbox and secure
with 'C' clip.
10.Clean oil pipe unions and fit new 'O' rings.
11.Position and tighten pipe unions to gearbox.
12.Position and tighten oil cooler pipe clamps.
13.Position and tighten oil cooler pipe clips to
engine sump and alternator bracket.
14.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
15.Secure gearbox breather pipes to bulkhead
clip.
16. Up to 03 Model Year - If fitted: Connect 2
Lucars to differential lock warning lamp switch
and multiplugs to high/low ratio switch and
neutral sensor.
17. 03 Model Year onwards - If fitted: Connect
differential lock warning lamp switch multiplugs
to main harness.
18.Position cable tie and multiplug to transfer box
bracket.
19.Connect high/low ratio selector cable to
selector lever and secure with clevis pin. 20.Position high/low ratio selector cable to
abutment bracket and secure with 'C' clip.
21. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness.
22. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
23.Position handbrake backplate and tighten bolts
to 75 Nm (55 lbf.ft).
24.Fit hand brake drum and tighten screw.
25.Remove bolts securing tool LRT-99-008A to
gearbox.
26.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
27.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
28.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
29.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
31.Position intermediate silencer and secure to
mounting rubbers.
32.Clean silencer and tail pipe mating faces.
33.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
34.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
35.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
36.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
37.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
38.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
39.Connect battery earth lead.
40.Fit battery cover and secure with fixings.
41.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.

BRAKES
DESCRIPTION AND OPERATION 70-19
ABS sensors
The ABS sensors supply the SLABS ECU with a sinusoidal speed signal from each wheel. An inductive sensor,
installed in the hub bearing of each wheel, senses off a 60 tooth exciter ring integrated into the inner race of the hub
bearing. Each ABS sensor has a fly-lead connecting it to the vehicle wiring.
HDC switch
The HDC switch is a latching push switch installed on the fascia, in the switchpack inboard of the steering wheel.
When pushed in, the switch connects an ignition supply to the SLABS ECU to initiate HDC.
Warning indications
The SLABS ECU operates audible and visual warnings to convey brake system status.
Audible warning
A repetitive chime, at a frequency of 2 Hz, draws attention to warning lamp indications. The chime is produced on the
speaker in the instrument pack.
Warning lamps
1ABS warning lamp
2HDC fault warning lamp
3ETC warning lamp4HDC information warning lamp
5Brake warning lamp (all except NAS)
6Brake warning lamp (NAS only)
The following brake system warning lamps can be found in the instrument pack:
lA red brake graphic (all except NAS vehicles) or red BRAKE legend (NAS vehicles), to warn of low brake fluid
level, handbrake on and brake control system failure affecting EBD.
lAn amber ABS graphic, to warn of brake control system failure affecting the ABS function.
lAn amber TC graphic, to warn of brake control system failure affecting the ETC function.
lTwo inclined vehicle graphics, one amber (fault) and one green (information), to indicate operating status of HDC
and to warn of brake control system failure affecting the HDC function.
Each warning lamp is illuminated by a separate LED. The ABS, brake and ETC warning lamps are continuously on
while illuminated; the two HDC warning lamps are either continuously on or flash at a frequency of 2 Hz while
illuminated.

BRAKES
DESCRIPTION AND OPERATION 70-25
DESCRIPTION AND OPERAT ION
Handbrake component layout
1Warning switch
2Handbrake lever
3Cable
4Protective sleeve
5Drum brake6'C' clip
7Threaded sleeve
8Adjuster wheel
9Base plate
10Transmission tunnel

BRAKES
70-26 DESCRIPTION AND OPERATION
Description
General
The handbrake consists of a drum brake, installed on the rear of the transfer box, operated by a cable connected to
a handbrake lever between the front seats.
Handbrake lever
The handbrake lever is mounted on a base plate which attaches to the transmission tunnel. A conventional ratchet
and thumb operated release button are incorporated for locking and unlocking the lever. A warning switch on the base
of the lever operates the brake warning lamp in the instrument pack. While the handbrake is applied the warning
switch connects an earth to the instrument pack which, if the ignition is on, illuminates the brake warning lamp. In
some markets, the instrument pack performs a bulb check of the brake warning lamp each time the ignition is switched
on.
Cable
The handbrake cable consists of inner and outer cables installed between the handbrake lever and the drum brake.
A protective sleeve is installed on the cable to protect the cable from heat from the exhaust system. Handbrake
adjustment is provided by a threaded sleeve installed on the outer cable where it locates in the handbrake lever.
Turning an adjuster wheel, which is keyed to the threaded sleeve and secured by a 'C' clip, alters the effective length
of the outer sleeve and consequently changes the handbrake lever movement needed to apply the drum brake.

BRAKES
DESCRIPTION AND OPERATION 70-27
Drum brake
1Drum
2Drum securing bolt
3Backplate4Cable
5Backplate securing bolt
The drum brake consists of a backplate attached to the transfer box casing and a drum attached to the transfer box
rear output shaft. When the handbrake lever is applied, the movement is transmitted by the inner cable to a lever on
one of the brake shoes on the backplate. The lever pivots against the brake adjuster rod, which forces the shoes apart
and into contact with the drum. Brake shoe to drum clearance is set by an adjusting bolt on the rear of the backplate.

BRAKES
ADJUSTMENTS 70-29
ADJUST ME NTS
Handbrake
$% 70.45.09
Check
1.Apply the handbrake lever 3 notches on the
ratchet. The handbrake should be fully
operational.
2.If the handbrake is not fully operational, the
brake shoes and/or the handbrake cable need
adjusting.
Adjust
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Ensure handbrake lever is fully released.
3.Tighten brake shoe adjusting bolt until brake
drum is locked, then back off adjusting bolt 1.5
turns. Check that the brake drum is free to
rotate.
4.Recheck handbrake operation.If handbrake is
not fully applied with 3 notches on the
ratchet, the handbrake cable requires
adjustment.
5.Remove switch panel from centre console.

+ WINDOWS, REPAIRS, Switch -
console.
6.Release handbrake lever gaiter from centre
console.7.Rotate adjuster anti-clockwise to increase
cable tension (reduce notches) or clockwise to
decrease cable tension (increase notches).
8.Recheck handbrake operation.
9.Secure handbrake lever gaiter to centre
console.
10.Fit switch panel to centre console.

+ WINDOWS, REPAIRS, Switch -
console.
11.Remove stand(s) and lower vehicle.

BRAKES
70-36 REPAIRS
Cable - handbrake
$% 70.35.25
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Remove clip and clevis pin securing cable to
hand brake lever.
3.Remove brake shoes from hand brake
assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.From below the vehicle, pull handbrake cable
through transmission tunnel.
5.Release handbrake cable from backplate. Refit
1.Fit and secure handbrake cable to backplate.
2.Position hand brake cable through
transmission tunnel.
3.Fit brake shoes to hand brake assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.Align cable to hand brake lever and secure with
clip and clevis pin.
5.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
6.Adjust handbrake.

+ BRAKES, ADJUSTMENTS,
Handbrake.

BRAKES
70-40 REPAIRS
Brake shoes - handbrake
$% 70.45.18
Remove
1.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
2.Remove screw and remove brake drum. 3.Remove 2 washers, springs and pins retaining
brake shoes to back plate.
4.Release return springs and remove brake
shoe.
5.Remove retaining spring securing abutment
lever to back plate.
6.Release remaining brake shoe from brake
cable, remove brake shoe and collect return
springs.
7.Remove adjuster plungers.
8.Remove 'C' clip securing cable lever to brake
shoe. Remove flat washer, lever, 2 Belleville
washers and pivot pin.

BRAKES
REPAIRS 70-41
Refit
1.Clean components with brake cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
2.Lubricate cable lever pivot pin.
3.Fit pivot pin to shoe, fit cable lever washers and
secure with 'C' clip.
4.Fit adjuster plungers.
5.Fit shoe to brake cable, align to back plate and
adjuster. Secure shoe to back plate with pin,
spring and washer.
6.Fit abutment plate to brake shoe.
7.Fit return springs with remaining shoe. Secure
shoe to back plate with pin, spring and washer.
8.Fit abutment plate retaining spring.
9.Clean brake drum and mating face.
10.Position brake drum and tighten retaining
screw.
11.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
12.Adjust handbrake.

+ BRAKES, ADJUSTMENTS,
Handbrake.