1995 LAND ROVER DISCOVERY brakes

BRAKES
17
REPAIR REAR BRAKE CALIPER ASSEMBLY
LH Rear Caliper illustrated
Key to caliper
1. Caliper
2. Bleed screw
3. Pad retaining springs
4. Brake pads
5. Piston6. Wiper seal retainer
7. Wiper seal
8. Fluid seal
9. Retaining pins

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

BRAKES
19
REPAIR SENSORS - REAR
Service repair no - 70.65.31
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush must be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor electrical connections,
located above rear axle.
3.Remove sensor from its locating clip.
4.Remove bolts securing mudshield.
5.Using a suitable lever, pry sensor from mounting
bush.
6.Release harness cable ties, remove sensor lead
from vehicle.
7.Remove sensor bush.
Refit
8.Fit new sensor bush.
9.Lightly grease new sensor using silicone grease.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
10.Push sensor through bush until it touches exciter
ring. Sensor will be 'knocked back' to correct
position when vehicle is driven.
11.Secure harness in position.
12.Reconnect sensor electrical connection.
13.Drive vehicle to ensure ABS warning light is
extinguished.STOP LIGHT SWITCH ABS
Service repair no - 86.65.51
Remove
1.Turn ignition off. Disconnect battery negative
lead.
2.Remove lower trim panel.
3.Disconnect multiplug to switch.
4.Depress brake pedal access front of switch.
5.Pull sleeve and plunger of switch FULLY
forward.
6.Remove switch rearwards
NOTE: If switch is difficult to release,
check sleeve is FULLY forward.
Refit
7.Pull sleeve and plunger of switch fully forward.
8.Depress brake pedal, fit switch. Ensure retaining
clips are FULLY located.
9.Hold switch firmly in place, pull brake pedal back
fully to set switch.
10.Reconnect battery and turn ignition on.
11.Check switch operation by slowly depressing
brake pedal and checking that the switch clicks
twice.
12.Check stop lamps go off when pedal is released.
13.Recheck switch is securely fitted.
14.Operation may be checked using Testbook.

70BRAKES
20
REPAIR STOP LIGHT SWITCH - NON ABS
Service repair no - 86.65.51
Remove
1.Disconnect battery negative lead.
2.Remove lower dash panel.
3.Depress foot brake.
4.Remove rubber protector from switch, if fitted.
5.Remove hexagon nut.
6.Withdraw switch.
7.Disconnect electrical leads.
Adjust
8.With switch still in position and multiplug
disconnected, connect an ohmmeter across
switch terminals.
9.Screw switch in until open circuit exists across
terminals with pedal released and continuity
exists as soon as pedal is depressed.
10.Tighten locknut.
CAUTION: Ensure switch does not prevent
brake pedal returning fully.
Refit
11.Reverse removal procedure.

BRAKES
21
REPAIR BRAKE COMPONENTS ABS
Left hand drive shown. On right hand drive vehicles the master cylinder and servo unit only move
position.
KEY
1. Connector-double elbow
2. Rear left brake
3. Modulator to rear left brake
4. Modulator to master cylinder
5. Modulator to pressure reducing valve upper
6. Electrical connection
7. Modulator unit
8. Nut, mounting bush and cup
9. Modulator to front left brake
10. Front left brake
11. Electrical connection12. Modulator to front right brake
13. Modulator to pressure reducing valve lower
14. Master cylinder to pressure reducing valve lower
15. Front right brake
16. Bolt
17. Pressure reducing valve
18. Modulator to pressure reducing valve upper
19. Master cylinder
20. Servo unit
21. Modulator to rear right brake
22. Rear right brake

70BRAKES
22
REPAIR MODULATOR UNIT
Service repair no - 70.65.45
WARNING: New modulator units are
supplied in a shock absorbing pack
marked with a use by date. The new
modulator will contain hydraulic brake fluid within
the valve block and all ports plugged.
Modulator units must be handled with care the
following must be avoided:- any impact, use of
compressed air on any of the hydraulic ports,
removing plugs to connection ports before fitting
unit.
Remove
1.Refer to the illustration of brake components
ABS. For details of modulator unit and hydraulic
pipe connections to it.
See Brake
Components ABS
2.Refer to general brake service practice.See
General Brake Service Practice
3.Check new modulator unit is packaged in
accordance with the WARNING above.
4.Disconnect battery negative lead.
5.Remove the two electrical plugs.
6.Identify 8 pipe to modulator connections for
correct reassembly.
7.Disconnect 8 pipe unions.
8.Remove nuts securing modulator to mounting
bracket.
9.Remove modulator unit.
10.Remove mounting bushes and cup.
Refit
11.Fit mounting bushes and cup to new modulator.
12.Fit modulator unit to mounting bracket.
13.Fit 8 pipes to modulator connections. Pipes
mustbe connected to correct port. Tighten to
15Nm.
14.Bleed the complete hydraulic system.See
Brake System Bleed
15.Check system function using the 'Testbook'
diagnostics
16.Test operation of brakes.ELECTRONIC CONTROL UNIT ABS
Service repair no - 70.65.01
Remove
For location of the ECU.
See Description and
operation, ABS Components
1.Disconnect battery negative lead.
2.Remove retaining bolt and lower alarm system
ECU and relay mounting bracket into passenger
footwell.
3.Remove two screws and detach ECU complete
with harness plug from mounting bracket.
4.Release ECU plug retaining clip.
5.Move plug in direction of arrow and release
hooked end of plug from retaining post.
Refit
6.Reconnect ECU harness plug ensuring that it is
firmly located and retaining clip secures plug.
7.Reverse removal procedure.

BRAKES
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Brakes
Brake pipe connections to:
- Modulator unit 15.................................................................................
- Brake calipers 15.................................................................................
- Master cylinder 15................................................................................
Jump hoses to calipers 15..............................................................................
Bleed screws 15..............................................................................................
Brake caliper to swivel pin housing 82............................................................
Servo assembly to pedal box 26.....................................................................
Master cylinder to servo 26.............................................................................

BRAKES
1
SERVICE TOOLS BRAKE SERVICE TOOLS
LRT-70-500 Brake piston compressor
18G 672