1995 LAND ROVER DISCOVERY service

BRAKES
5
REPAIR
10.Ease reservoir out of master cylinder taking care
to ensure that two outlet ports on bottom of
reservoir do not become damaged during this
process.
11.Withdraw two reservoir seals from master
cylinder inlet ports. Note for reassembly these
seals are different. Discard seals.
12.Remove retaining ring and 'O' ring seal from
machined outer surface of master cylinder.
Discard both seal and retaining ring.
13.Remove guide ring, which supports primary
plunger assembly, from mouth of master
cylinder. Place to one side for reassembly, note
this component is not part of service kit.
14.Pull primary plunger assembly out of master
cylinder.

70BRAKES
6
REPAIR
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
15.The secondary plunger assembly will remain at
bottom of master cylinder bore. Remove tapping
assembly on a piece of wood until plunger
appears at cylinder mouth, carefully pull plunger
out of master cylinder.
16.If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
remove it from bottom of master cylinder bore
and discard.
17.Clean all parts with unused brake fluid. Place
cleaned parts onto a clean sheet of paper.
Inspect cylinder bore and plungers for signs of
corrosion, ridges and score marks. Provided
working surfaces are in perfect condition, new
seals from a Girling Service repair kit may be
used.
Renewing secondary plunger seals
18.Remove following components from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded off and polished is required to
remove 'L' seal. DO NOT damage
secondary plunger.
(A) Springs
(B) Seal retainer
(C) Recuperating seal (primary cup)
(D) Washer
(E) 'L' seal

BRAKES
9
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
NOTE: The filter, non-return valve and
grommet, are the only serviceable
components, in event of failure or damage
fit a new unit.
1.Disconnect battery negative lead.
2.Disconnect electrical plug to low fluid level
switch.
3.Thoroughly clean immediate area around all
master cylinder outlet ports. Remove each brake
pipe, sealing each pipe and outlet port to prevent
ingress of foreign matter.
4.Disconnect vacuum supply hose to servo.
5.Remove lower dash panel to gain access to
servo push rod to brake pedal.
6.Remove clevis pin securing servo push rod to
brake pedal.
7.Remove two nuts and plain washers securing
servo.
8.Remove servo and master cylinder assembly.
9.Drain brake fluid into a suitable container. (If
master cylinder is kept horizontal it is not
necessary to drain fluid).10.Detach spacer from pedal box mounting face of
servo.
NOTE: Retain spacer for reassembly. The
spacer ensures stringent pedal to servo
operating dimensions are maintained.
11.Remove master cylinder from existing servo and
refit to new servo, if fitting new unit.
Refit
12.Fit spacer to servo.
13.Fit servo to pedal box.
14.Lightly grease brake pedal around area servo
push rod pivots.
15.Fit push rod to lower hole of brake pedal. Fit
clevis pin and clip.
16.Secure servo with two nuts and plain washers.
Tighten nuts to
26 Nm.
17.Refit lower dash panel.
18.Fit master cylinder to servo, refit nuts, plain and
spring washers. Tighten nuts to
26 Nm.
19.Remove all sealing plugs. Refit brake pipes to
respective ports. Tighten brake pipes to
15 Nm.
20.Refit vacuum supply hose.
21.Fill master cylinder to correct level using correct
grade of brake fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
22.Bleed brake system.See Brake System Bleed

70BRAKES
10
REPAIR FRONT BRAKE PADS
Service repair no - 70.40.02
Service tool:
LRT.70-500 - Piston clamp
Remove
1.Remove front road wheels.
See WHEELS AND
TYRES, Repair, Wheels
2.Clean exterior of calipers.
3.Remove split [cotter] pin from retaining pins.
4.Remove pad retaining pins and anti-rattle
springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clamp LRT-70-500 press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads.
9.Fit pad retaining pins and anti-rattle springs.
Secure with new split [cotter] pin.
10.Apply service brake pedal several times to locate
pads.
11.Check fluid reservoir. Top up if necessary, using
correct grade of fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids

BRAKES
11
REPAIR REAR BRAKE PADS
Service repair no - 70.40.03
Service tool:
LRT-70-500 - Piston clamp
Remove
1.Remove rear road wheels.
See WHEELS AND
TYRES, Repair, Wheels
2.Disconnect battery negative lead.
3.Clean exterior of calipers.
4.Remove pad retaining pins and springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clamp LRT-70-500 press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.Refit
8.Insert brake pads.
9.Position pad retaining springs, fit new pins and
spread ends.
10.Apply service brake pedal several times to locate
pads.
11.Check fluid reservoir, top up if necessary, using
correct grade of fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids

BRAKES
13
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.03
Service repair no - 70.55.16
Service tool:
LRT-70-500 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen front wheel retaining nuts, raise front of
vehicle, lower onto axle stands, remove 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 [cotter] pin, retaining pins and
springs, withdraw pads. If refitting pads, identify
them for assembly to original locations.
6.Loosen bolts and remove caliper.
Repair
Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special tool LRT-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
15
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Service tool:
LRT-50-700 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen rear road wheel nuts. Jack up vehicle,
lower onto axle stands, remove wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
3.Remove brake pipe(s) from rear brake caliper(s).
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 two bolts, withdraw caliper from axle.
Repair
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.

70BRAKES
18
REPAIR SENSORS - FRONT
Service repair no - 70.65.32
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect required sensor electrical
connection, located on inner wing [fender] panel.
3.Remove sensor lead from clips.
4.Clean area surrounding sensor to prevent
ingress of dirt. Using a suitable lever pry sensor
from mounting bush.
5.Release harness cable ties, remove sensor lead
from vehicle.
6.Remove top swivel retaining bolts complete with
brake jump hose and sensor seal. Remove
sensor bush.
Refit
7.Insert new sensor bush and seal.
8.Refit brake jump hose bracket, coat bolts with
Loctite 270.
9.Lightly coat new sensor using EP 90 oil. Push
sensor through bush until it contacts exciter ring.
Sensor will be 'knocked back' to correct position
when vehicle is driven.
10.Secure sensor lead in original position.
11.Reconnect sensor electrical connection.
12.Drive vehicle to ensure ABS warning light is
extinguished.
SENSOR RINGS
The rear sensor ring is assembled to the rear brake
disc to form part of the rear hub assembly.
See
REAR AXLE AND FINAL DRIVE, Repair, Rear Hub
Assembly
The front sensor ring is a toothed ring on the axle
shaft which forms part of the front stub axle assembly.
See FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS