1996 LAND ROVER DEFENDER brakes

10MAINTENANCE
2
MAINTENANCE BATTERY CONNECTIONS
NOTE: The vehicle may be fitted with an
alarm and immobilisation system using a
battery backed-up alarm sounder.
See
ELECTRICAL, Repair, Battery
Disconnect battery leads, clean and grease with
petroleum jelly, including battery terminals.
CHECK OPERATION OF DOOR SWITCHES
When a Vehicle Immobilisation and Alarm System is
fitted it is important that all door and bonnet switches
operate correctly, otherwise perimeter and interior
protection may not function if a door or the bonnet is
opened.VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp alignment.
CHECK ROAD WHEELS AND TYRES
Check road wheels for damage.
Check tyres, including spare, for compliance with
manufacture's specificaton.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth.
See INTRODUCTION,
Information, wheels and tyres
Check/adjust tyre pressures.See WHEELS AND
TYRES, Repair, Tyres pressures
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION OF DISCS
Check thickness of brake pads, and renew if thickness
is less than 3,00 mm (0.12 in). Check brake pads for
oil contamination and fit a new set, if necessary,
See
BRAKES, Repair, front brake pads
orSee
BRAKES, Repair, rear brake pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to carry
out this operation.
See STEERING, Adjustment,
front wheel alignment
CHECK OPERATION OF ALL DOORS/TAILGATE,
BONNET AND LOCKS
LUBRICATE ALL DOOR/TAILGATE HINGES, AND
DOOR CHECK/LOCK MECHANISMS

51REAR AXLE AND FINAL DRIVE
2
REPAIRREV: 05/99 Refit
15.Position axle and fit lower links. Tighten fixings
to
176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair, Anti-roll bar
links
.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to
176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to
47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)
24.Remove rear chassis support.
25.Bleed brake system
See BRAKES, Repair,
brake system bleed
.

51REAR AXLE AND FINAL DRIVE
6
REPAIRREV: 05/99 Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play.
14.Back off adjusting nut 90°and tighten to
10 Nm
(7 lbf/ft).
15.Fit a new lock washer.
16.Fit locknut. Tighten to
50 Nm (37 lbf/ft).
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub. Tighten bolts to
65 Nm (48
lbf/ft).
19.Fit circlip and dust cap.
20.Fit brake disc shield and brake caliper. Tighten
bolts to
82 Nm (61 lbf/ft).
21.Bleed brake systemSee BRAKES, Repair,
Brake system bleed
.
22.Fit road wheel, remove axle stands and tighten
road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
23.Operate footbrake to locate brake pads before
driving vehicle.

FRONT AXLE AND FINAL DRIVE
3
REPAIR REV: 05/99 Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play.
14.Back off adjusting nut 90°and tighten to
10 Nm
(7 lbf/ft).
15.Fit a new lock washer.
16.Fit locknut. Tighten to
50 Nm (37 lbf/ft).
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub. Tighten bolts to
65 Nm (48
lbf/ft).
19.Fit original drive shaft shim and secure with a
circlip.
20.To check drive shaft end play, mount a dial
gauge using bracketLRT-99-503and rest pin in
a loaded condition on end of drive shaft.
21.Fit a suitable bolt to threaded end of drive shaft.
Move drive shaft in and out noting dial gauge
reading. End play should be between 0,08 to
0,25 mm.
22.If end play requires adjustment, remove circlip,
measure shim thickness and fit an appropriate
shim to give required end-play.
23.Remove bolt from drive shaft, fit circlip and dust
cap.
24.Fit brake disc shield and brake caliper. Tighten
fixings to
82 Nm (60 lbf/ft).
25.Bleed brake systemSee BRAKES, Repair,
Brake system bleed
.
26.Fit road wheel, remove axle stands and tighten
road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
27.Operate footbrake to locate brake pads before
driving vehicle.

57STEERING
2
REPAIR
13.Disconnect 3 switch multi-plugs.
14.Slacken clamp screw on top of switch cluster
and withdraw switch assembly.
15.Note position of harness leads on back of starter
switch and disconnect lucars. If fitted, remove
alarm system passive coil from switch
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
16.Using a punch or stud extractor remove 2 shear
bolts securing switch to column.
17.Remove switch and collect 2 plain washers
between switch and clamp.
18.Remove brake pedal box
See BRAKES,
Repair, Brake pedal
.
19.Remove bolt securing tie-bar to steering column,
behind instrument panel.
20.Remove 2 bolts securing column lower support
to mounting bracket.
21.Remove bolts securing two halves of top clamp
and bolts that secure top half of clamp to
bulkhead.
22.Remove clamp and rubber packing.
23.Remove 2 bolts securing column main support
bracket to bulkhead.
24.Remove steering column and main support
bracket from vehicle.

STEERING
3
REPAIR REV: 05/99
NOTE: The steering column is a non
serviceable component and can only be
serviced as a complete assembly.
25.Fit main support bracket and padding to steering
column and manoeuvre column into position in
vehicle.
26.Loosely secure main support bracket and
harness bracket to bulkhead.
27.Loosely fit clamp and rubber packing strip to
column.
28.Loosely secure lower end of column to lower
support bracket.
29.Loosely secure clamp bracket to main support
bracket.
30.Working inside vehicle cab, fit tie-bar to column
bracket and secure with single bolt to
22 Nm (16
lbf/ft).
31.Finally, tighten main support bracket, clamp
bracket, upper clamp, and lower support bracket
nuts and bolts. (M6 bolts
9 Nm (6 lbf/ft),M8
bolts
22 Nm (16 lbf/ft).
32.Fit brake pedal boxSee BRAKES, Repair,
Brake pedal
.
33.Fit steering lock/switch in position and rotate
steering column inner shaft to line up slot with
switch plunger.
34.Secure lock to column with clamp and shear
bolts. Evenly tighten bolts but do not shear them.
35.Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
36.Fully tighten switch retaining bolts until heads
shear.
37.Connect electrical leads to rear of switch. Fit
alarm system passive coil, if applicable.
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
38.Fit switch assembly on steering column and
tighten clamping screw.
39.Connect switch assembly multi-plugs and
electrical leads to main harness.
40.Offer up instrument panel, connect speedometer
cable, multi-plugs and electrical leads to main
harness. If applicable, fit vehicle alarm system
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system
.
41.Secure panel with 4 screws.
42.Locate top half of nacelle in position and fit to
switch gaiters/grommets.43.Fit lower half of nacelle and loosely tighten fixing
screws.
44.Ensure switch gaiters/grommets are correctly
located and fully tighten fixings.
45.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
46.Fit steering wheel with finisher attachment lug at
bottom, ensuring that indicator cancelling forks
locate in cancelling ring slots.
47.Secure wheel with nut and new shake-proof
washer. Tighten to
43 Nm (32 lbf/ft).
48.Fit steering wheel decal.
49.If necessary, fit new universal joints to support.
Note that long joint is fitted to short length of
shaft and short joint to long end. Joints can only
be fitted one way to shaft.
50.With steering lock engaged and road wheels in
straight ahead position, align reassembly marks,
and fit collapsible shaft assembly with long leg of
shaft to steering box. Fit pinch bolts and tighten
to
25 Nm (18 lbf/ft).

BRAKES
1
DESCRIPTION AND OPERATION DESCRIPTION
The mechanical components of the hydraulic braking
system consists of four piston caliper disc brakes at
the front and two piston caliper disc brakes at the rear.
Vented front brake discs are fitted as standard on
110/130 models, while 90 models have solid discs.
However, on 90 models with a heavy duty chassis,
vented front discs may also be fitted.A cable controlled parking brake operates a single
drum brake mounted on the output shaft of the
transfer gearbox and is completely independent of the
main braking system.
The basic hydraulic system involves 2 separate and
independent primary and secondary circuits which
permits a degree of braking should a fault occur in
one of the circuits. The primary circuit operates the
rear brake calipers and the secondary circuit the front
brake calipers.
Master cylinder components
1.Secondary plunger
2.Secondary spring
3.Recuperation seal4.Primary spring
5.Recuperation seal
6.Primary plunger

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.