1996 LAND ROVER DEFENDER ESP

PROPELLER SHAFTS
1
OVERHAUL REV: 05/99 PROPELLER SHAFT
Service repair no - 47.15.11 - Front
Service repair no - 47.15.12 - Rear
1.Thoroughly examine universal joint for signs of
damage or wear. Replace if necessary.
2.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance, mark
position of spider pin lubricator relative to
journal yoke ears, before removing propeller shaft
joint.
3.Remove circlips, and grease nipple.
4.Tap yokes to eject bearing cups.5.Remove bearing cups and spider.
6.Repeat instructions 4 to 7 for opposite end of
propeller shaft if necessary.
7.Clean yokes and bearing cup locations.
Assembly
8.Remove bearing cups from new spider.
9.Check all needle rollers are present and
positioned in bearing cups.
10.Ensure bearing cups are one-third full of
lubricant
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
.
11.Enter new spider with seals into yokes of sliding
member flange.
12.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
13.Insert opposite bearing cup into flange yoke.
14.Press both cups into place.
15.Press each cup into its respective yoke up to
lower land of circlip grooves. Damage may be
caused to cups and seals if cups pass this point.
16.Fit circlips and check no end float exists.

70BRAKES
2
DESCRIPTION AND OPERATION REV: 05/99 OPERATION
Master cylinder
A tandem master cylinder, which is assisted by a light
weight, short, compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank.
When the footbrake is applied, the primary plunger
assembly moves up the cylinder bore and the
pressure created acts in conjunction with the primary
spring to overcome the secondary springs, thus
moving the secondary plunger assembly up the bore.
At the same time initial movement of both plungers
takes the recuperating seals past the cut-off holes in
the cylinder chambers 'A' and 'C',see J6321, and
applies pressure to the fliud in those chambers, which
is directed to the respective circuits.
The fluid in chambers 'B' and 'D'is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers 'A' and
'C'and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers 'B' and 'D'to flow through the holes
in the plungers, over the collapsed seals and into
chambers 'A' and 'C'respectively. The movement of
fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers 'A' and 'C'to move through the cut off holes
into the fluid reservoir.The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied. Power
is obtained from a vacuum pump located on the RH
side of the engine cylinder block. The vacuum is
applied to both sides of a flexing diaphragm, and by
admitting atmosheric pressure to the rear diaphragm,
assistance is obtained. The servo unit is mounted
between the brake pedal and master cylinder and is
linked to these by push rods. Should a vacuum failure
occur, the two push rods will act as a single rod
allowing the brakes to function in the normal way,
although more effort will be required to operate the
brake pedal.
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate as a bulb
check when the ignition is switched on and
extinguishes when the engine is running and the
handbrake is released. A hydraulic failure in the
system will result in fluid loss, causing the warning
light to illuminate.
On 90 models a pressure reducing valve (PRV), fitted
to the RH bulkhead in the engine compartment,
maintains the braking balance, see J6322. Pressure
to the rear calipers is regulated by the PRV, this valve
is of the failure by-pass type, allowing full system
pressure to the rear brake calipers in the event of a
front (secondary) circuit failure.
NOTE: In some countries, a pressure
reducing valve may be fitted to 110 models
to conform to legal requirements.

70BRAKES
10
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.05
Service repair no - 70.55.16
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
Remove
1.Remove front road 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 pin, retaining pins and springs,
withdraw pads. If refitting pads, identify them for
assembly to original locations.
6.Remove 2 bolts and withdraw caliper from swivel
housing.
WARNING: Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special toolLRT-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
13
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Before starting repair refer to General brake service
practice
See General Brake Service Practice.
Remove caliper
1.Remove rear road wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
90 Models
110/130 Models
3.Remove brake pipe from rear brake caliper.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 2 bolts and withdraw caliper from rear
axle.
Repair
WARNING: 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.
13.Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.

70BRAKES
4
OVERHAUL Assembling master cylinder
CAUTION: It is important that the 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.
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.
16.Fit new swirl tube to bottom of cylinder bore.
17.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.
18.Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19.Fit original guide ring to support primary plunger.
20.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: 'O' ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.21.Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22.Fit two new reservoir seals in their respective
ports.
23.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24.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.
25.Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27.Fit master cylinder to servo
See Repair,
Master cylinder
.
28.Reconnect battery, and road test vehicle.

AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable, but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour seek fresh air. If unconscious
remove to fresh air. Apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, R134a should be
handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.

AIR CONDITIONING
7
REPAIR EVAPORATOR - LH DRIVE
Service repair no - 82.25.20
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Release 3 nuts and remove mounting bracket
from underneath unit casing.
4.Remove 7 screws securing outlet duct to
heater/cooler unit.
5.Carefully break sealing compound around edge
of duct and pull ducting from unit.
6.Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
7.Remove 4 screws and 4 nuts from top of cover.
8.From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
9.At side of unit remove 2 screws adjacent to air
intake aperture.
10.Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
temperature probe which is inserted in
evaporator matrix through top cover.
11.Lift support plate and insulation pad from heater
matrix.
12.From bottom of unit casing, remove 3 screws
adjacent to dump valve outlet, and screws next
to heater matrix pipes.

AIR CONDITIONING
9
REPAIR EXPANSION VALVE - LH DRIVE
Service repair no - 82.25.01
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Remove 7 screws securing outlet duct to
heater/cooler unit.
4.Break sealing compound around edge of duct
and pull duct from unit.
5.Remove all fixing screws securing top cover
seam and cover sides to main casing.
6.Remove 4 screws and 4 nuts from top of cover.
7.Break sealing compound from unit casing and
top cover.
8.Lift off top cover, release grommet and feed
blower motor wiring and air flap operating rod
through respective apertures. Note thermostat
temperature probe which is inserted in top of
evaporator.
9.Release 2 clips securing expansion valve sensor
and lagging to low pressure pipe.
10.Unscrew union securing expansion valve to
evaporator high pressure pipe.
11.Remove expansion valve, complete with high
pressure pipe.
12.Disconnect high pressure pipe from expansion
valve.
13.Discard all pipe connection 'O' rings.
14.Clean sealing compound from all joints of main
casing, top cover and outlet duct.
Refit
15.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
16.Fit high pressure pipe to new expansion valve.
17.Fit expansion valve to evaporator pipe
connector.
18.Position valve sensor at low pressure pipe and
secure with lagging and clips.
19.Apply sealing compound around top edge of
main casing.
20.Feed blower motor wiring through top cover and
fit grommet.
21.Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
22.Apply sealing compound to joint face of blower
motor outlet duct.
23.Locate duct over blower motor outlet and secure
to casing.
24.Fit heater/cooler unit
See Heater/cooler unit.