1995 LAND ROVER DISCOVERY Workshop Manual

BRAKES
7
REPAIR 19.Coat new seals in unused brake fluid. Fit 'L' seal
to plunger.
20.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21.Fit new swirl tube to bottom of cylinder bore.
22.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23.Fit new primary plunger assembly using same
method as for secondary plunger.
24.Fit original guide ring to support primary plunger.
25.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll 'O' ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26.Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27.Fit two new reservoir seals in respective ports.
28.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29.Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30.Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33.Fit brake pipes to master cylinder. Tighten to
15Nm.
34.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35.Bleed system.See Brake System Bleed
36.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

70BRAKES
8
REPAIR MASTER CYLINDER ASSEMBLY NON ABS
Key to master cylinder
1. Water ingress seal
2. Transfer housing
3. Vacuum seal
4. Guide ring
5. Retaining ring
6. 'O' ring seal7. Primary plunger assembly
8. 'L' seal
9. Secondary plunger
10. Washer
11. Recuperating seal (primary
cup)
12. Seal retainer13. Springs (2 off)
14. Swirl tube
15. Master cylinder body
16. Reservoir seals
17. Reservoir
18. Low fluid level switch and
cap
NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings. If debris is
found, carefully remove, re-clean cylinder and re-check.

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

70BRAKES
12
REPAIR FRONT BRAKE CALIPER ASSEMBLY
Key to caliper
1. Caliper
2. Bleedscrew
3. Antirattle springs
4. Pad retaining pins
5. Split [cotter] pin
6. Friction pads
7. Piston
8. Wiper seal retainer
9. Wiper seal
10. Fluid seal
11. Brake disc

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.

70BRAKES
14
REPAIR Assemble outboard pistons
13.Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15.Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16.Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17.Fit caliper, tighten bolts evenly to
82 Nm.
18.Connect brake flexible hoses to caliper. Tighten
to
15 Nm.
19.Remove hose clamps.
20.Insert pads. Fit pins and springs, secure using
new split [cotter] pin.
21.Bleed brake system.
See Brake System Bleed
22.Press brake pedal firmly several times to locate
friction pads.
23.Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to
130 Nm.
24.Road test vehicle. Note that new friction pads
require 'bedding-in', this may take several
hundred miles before brakes are at maximum
efficiency.