LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Front Disc Brake - Front Disc Brake
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: i6 gas oli ne front dis c brake s hown; TD4 dies el front dis c brake si mil ar.
ItemPart NumberDescription1-Ant i-lock Brake Sys tem (ABS) s ensor cable
2-ABS s ens or ret aining s crew

3-Dus t s hiel d
4-Dus t s hiel d ret aining s crew (3 off)
5-Brake dis c6-Brake dis c ret aini ng screw
7-Outer anti -s queal s him
8-Outer brake pad9-Inner brake pad
10-Inner ant i-s queal s him
11-Cal iper hous i ng spring12-Fi xed carri er
13-Cal iper pis ton seal
14-Cal iper pis ton15-Sl idi ng cal iper
16-Bus hed bolt rubber boot (2 off)
17-Bus hed bolt (2 off)18-Bus hed bolt dus t cap (2 off)
19-Cal iper bleed s crew
20-Bleed s crew cap21-Fl exi ble hos e
22-Fi xed carri er retai ni ng bolt (2 off)
23-Front Left-Hand (LH) wheel knuckle
OVERVIEW
The front brake as sembl y feat ures a venti lat ed brake dis c and cast -iron sl idi ng cal iper wit h s ingle act ing pi st on.
BRAKE DISC
ItemPart NumberDescription
A-Front brake dis c - i 6 gas ol ine vehicleB-Front brake dis c - TD4 di esel vehicle
The brake dis c i nst all ed to the 3.2 l it er i 6 gas ol ine vehicle is 316 x 28 mm (12.44 x 1.10 i n) diameter. The brake dis cins t al led t o t he 2.2 li ter TD4 dies el vehi cl e is 300 x 28 mm (11.81 x 1.10 in) diamet er. The brake di sc is s ecured t o thewheel knuckl e hub wi th a s ingle s crew and is al so ret ai ned by t he 5 wheel securi ng nut s .
Both types of front brake dis c are manufact ured wi th vent il at ion channel s , al lowi ng the di s c to achieve hi gh levels oft hermal st abil it y even during s evere braki ng.
The dis c i s cool ed as the forward mot ion of t he vehi cl e draws air t hrough the venti lat ion channel s, and acros s t he s urfacesof the di s c.
CALIPER ASSEMBLY

ItemPart NumberDescription
A-Front brake cal iper - i6 gas oli ne vehi cl eB-Front brake cal iper - TD4 dies el vehicle
The cal iper as sembl y compris es a fixed carrier and s li ding caliper. The fi xed carrier i s mounted t o s t raddle t he brake di scand is at t ached t o t he wheel knuckl e wit h 2 bol ts . The fixed carri er provides the locat ion for 2 brake pads t hat aremounted on ei ther s ide of t he brake di sc, and is formed wit h guide channel s t hat al low t he brake pads t o s li de toward t hedis c s urface.
• NOTE: The 2 fixed carrier ret aining bol ts are pre-appl ied wi th a t hread locking adhesi ve and mus t not be re-us ed duringmaint enance. New fixed carri er ret ai ning bolt s mus t be us ed and t he ori gi nal bolt s di scarded.
The s li di ng cal iper is mount ed over the fixed carrier and ret ains t he 2 brake pads wi thi n the cal iper as s embly. The s li di ngcal iper is secured t o t he fixed carri er wit h 2 bus hed bol ts , and i s formed wi th a hydraul ic chamber cont ai ning a 60 mm(2.36 in) di ameter pis t on and annular s eal.
The s li di ng cal iper is connect ed via a fl exi ble hos e t o t he brake s yst em hydrauli c circui t, and als o i ncorporates a bleeds crew for maint enance purposes .
The 2 bus hed bol ts are machined wi th a s mooth surface and are protect ed from di rt and moi st ure ingres s wi th a col laps iblerubber boot . The bushed bolt s all ow t he s li di ng caliper li mi ted l ateral movement along t he fi xed carri er.
A hous ing s pri ng is locat ed on t he outer s ide of t he brake dis c, and is connect ed wit h formed hooks between t he fixedcarri er and sl idi ng cal iper. During operat ion of t he brake, t he s pri ng is tens ioned as the sl iding cal iper moves toward thebrake dis c. The s pring as s is t s to move t he sl idi ng cal iper away from t he brake di sc as the brake is released.
An anti -s queal s him i s ins tal led on t he outs i de edge of each brake pad and reduces Nois e, Vibrat ion and Hars hnes s (NVH)from the brake component s duri ng operati on.
The brake pads are not i nst all ed wit h pad wear s ens ors .
BRAKE DUST SHIELD
A formed brake dust s hiel d is locat ed between t he wheel knuckle and brake di s c, and i s s ecured to the knuckl e wit h 3s crews .
The brake dus t shi eld i s handed t o t he rel evant s ide of t he vehicle and protects t he brake component s from cros s axl es tone t hrows . The brake dus t shi el d als o prevent s debris and brake dust from s preading t o other part s of t he vehi cl e.
PRINCIPLES OF OPERATION
Brake Application
As t he brake pedal i s applied, ini ti al hydrauli c pres s ure i s fel t in the s l iding cali per chamber caus ing t he pis t on to ext endt oward t he brake dis c. The moving pis t on cont act s t he inner brake pad, forci ng the pad al ong the fixed carrier guidechannels and i nto cont act wi th the i nner s ide of t he brake di sc.
As t he pis ton ext ends from t he cal iper chamber, it pas ses t hrough an i nternal annul ar seal located wit hi n t he cal iper

chamber. The movement of t he pis t on dis torts t he s hape of the s eal and cons equent ly, the s eal appl ies pres s ure on thepis t on out er s urface.
The s li di ng cal iper now react s and commences t o s li de along t he 2 bus hed bol ts , i n the oppos it e direct ion t o t he extendingpis t on. The s li ding cali per contacts t he outer brake pad, forcing t he pad along t he fi xed carri er gui de channels and i nt ocont act wit h the out er si de of the brake dis c. The hous ing s pri ng t hat i s att ached bet ween the fi xed carrier and s li dingcal iper is tens ioned as t he sl idi ng cal iper moves toward the brake dis c.
W i th bot h brake pads now in full cont act wit h the brake dis c and hydraulic pres sure act ing on the pi s ton, no furthermovement of t he pis t on and s li di ng cal iper is pos s ible. The force creat ed by the pi ston and cali per acti ng agai nst the brakepads increas es rapidly, t rapping t he brake di sc and sl owing t he vehi cl e.
Brake Release
As t he brake pedal i s rel eas ed, hydraul ic press ure in the cali per chamber coll apses and force i s no longer appl ied t o t hebrake pads. The brake pads are moved s li ght ly out wards by t he acti on of the rotat ing brake di s c, and t he caliper int ernalannul ar seal ret urns t o t he normal s hape. As t he s eal moves i t gri ps on the pi s ton out er s urface and wit hdraws t he pis t onint o t he chamber, suffi ci ent ly to provi de t he neces sary pad t o dis c clearance.
This acti on prevents t he pis t on from hol di ng t he inner brake pad agai nst t he dis c, and als o enables t he pis ton to protrudefurther from the cali per chamber to compens at e for brake pad wear.
W i th no pres s ure being appli ed t o the hydraul ic s yst em, t he hous i ng spring t ensi on is al s o rel ieved and the spring returnst o the normal pos i ti on. As t he housi ng s pri ng moves , t he att ached s l iding cali per i s moved away from the out er s i de of thedis c t o provide the neces s ary cl earance bet ween the out er brake pad and the brake dis c.

Publi s hed: 11-May-2011
Front Disc Brake - Front Disc Brake
Diagnosi s and Tes ti ng
For addit ional informat ion.REFER to: Brake Sys tem (206-00 Brake Sys tem - General Informati on, Diagnos is and Tes t ing).

Publi s hed: 11-May-2011
Front Disc Brake - Brake Pads
Removal and Inst all ati on
Removal
1. W ARNING: Do not work on or under a vehi cle s upported onl yby a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he front wheel s and ti res .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
2.
Remove t he brake pad s pri ng cl ip.3.
Remove t he 2 caliper guide pi ns .4.
5. CAUTION: Make s ure that no load i s placed on t he brakehos e.
Releas e t he brake caliper.
5.

Remove t he brake pads.
6.
Repeat t he above procedure for t he other s ide.
7.
Installation
1. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled. CAUTION: Make s ure that t he mati ng faces are cl ean and free
of foreign mat eri al and t hat no greas e is appl ied t o t he brake pad
guides .
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
1.
Inspect the cali per pi st on and s li de pin seals for damage.
2.
Pos it ion a bl eed jar cont aining a s mall quant it y of approved brake
fluid. Connect t he bleed t ube to the bl eed screw and loos en t he
s crew.
3.
Pres s t he pis t on int o t he cal iper hous ing and ti ght en t he bleed
s crew.
T orque: 8 Nm 4.
Di sconnect t he bleed t ube and remove t he jar.
5.
Inst all t he brake pads.
6.
Inst all t he brake caliper.
7.
8. CAUTION: Make s ure that the brake hose is not t wis ted and
i s correctl y located.
Inst all t he gui de pins and t ight en.
T orque: 28 Nm 8.
Inst all t he brake pad s pri ng cl ip.
9.
Repeat t he above procedure for t he other s ide.
10.
Inst all t he front wheel s and ti res .
11.

Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal andInst all at ion).
Depres s t he brake pedal s everal ti mes , check the fl ui d l evel in thebrake flui d res ervoir and t op-up wi th brake fl uid i f neces s ary.12.

Publi s hed: 11-May-2011
Front Disc Brake - Brake Disc
Removal and Inst all ati on
Removal
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he front wheel .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
2. 3. CAUTION: Make s ure that no load i s placed on
t he brake hos e.
Releas e t he brake caliper and t ie as ide.
3. Remove t he brake dis c.
4.
Installation Make s ure the brake di s c and hub mati ng s urfaces are cl ean.
1.
Inst all t he brake dis c and t ighten the Torx s crew.
T orque: 35 Nm 2.
3. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
3.

4. CAUTION: Make s ure that the brake hose is not t wis ted and
i s correctl y located.
Inst all t he brake caliper and t ighten t he new bol ts .
T orque: 200 Nm 4.
Inst all t he front wheel .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
5.
Depres s t he brake pedal s everal ti mes , check the fl ui d l evel in the
brake flui d res ervoir and t op-up wi th brake fl uid i f neces s ary.
6.