1999 LAND ROVER DEFENDER service

70BRAKES
6
REPAIR Refit
11.Fit rubber washer and servo assembly to pedal
box.
12.Fit nuts securing servo to pedal box and tighten
to14 Nm. (10 lbf.ft)
13.Position brake pedal to servo push rod.
14.Fit clevis pin and NEW split pin to secure brake
pedal to servo push rod.
15.Fit blanking grommets to each side of pedal box.
16.Attach pedal return springs to brake pedal.
17.Position closing panel and tighten screws to
lower’A’post.
18.Connect vacuum hose to servo.
19.Connect brake switch Lucars.
20.Fit brake master cylinder.See this Section.MODULATOR UNIT - ABS
Service repair no - 70.65.49
Remove
1.Position cloth under modulator to absorb any
fluid spillage.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
2.Disconnect 2 inlet brake pipe unions from pump
side of modulator.
3.Disconnect 4 outlet brake pipe unions from top
of modulator.
CAUTION: Plug the connections.
4.Disconnect 2 multiplugs from rear of modulator.
5.Loosen nut securing rear of modulator to
mounting bracket.
6.Remove 2 nuts securing front of modulator to
mounting bracket.
7.Release modulator from mounting bracket.
8.Disconnect multiplug from base of modulator.
9.Remove modulator.
Do not carry out further dismantling if
component is removed for access only.
10.Remove 3 mounting rubbers from old modulator
and fit to new.
ProCarManuals.com

BRAKES
7
REPAIR Refit
11.Position modulator to mounting bracket and
connect multiplug.
12.Fit modulator to mounting bracket and tighten
nuts to9 Nm (7 lbf.ft).
13.Connect 2 multiplugs to rear of modulator.
14.Remove plugs from brake pipes and modulator.
15.Clean brake pipe unions.
16.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
17.Tighten all unions to14 Nm (10 lbf.ft).
18.Bleed brake system.See Adjustment.
NOTE: To ensure correct operation, the
ABS system MUST be tested using
TestBook.BRAKE CALIPER - FRONT
Service repair no - 70.55.02
Remove
1.Loosen front road wheel nuts.
2.Raise front of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from pad retaining pins.
5.Remove brake pad retainers and springs.
6.Remove brake pads and shim if fitted.
7.Pull back brake hose shield.
8.Clamp brake hose using a suitable clamp.
9.Position container beneath brake caliper to
collect spillage.
10.Loosen brake pipe union and disconnect from
caliper.
11.Plug brake pipe and caliper connections.
12.Remove 2 bolts securing caliper.
13.Remove brake caliper.
ProCarManuals.com

70BRAKES
8
REPAIR Refit
14.Clean caliper to hub mating faces.
15.Position caliper to hub, fit bolts and tighten to82
Nm (60 lbf.ft).
16.Remove plugs from pipe to caliper connections
and wipe.
17.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
18.Apply a light film of grease to rear of brake pads.
19.Fit pads to calipers.
From 02MY, ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
20.Fit pad retainers and springs.
21.Fit split pins to retainers.
22.Remove brake hose clamp.
23.Bleed brakes.See Adjustment.
24.Depress brake pedal to seat pads onto discs.
25.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).BRAKE CALIPER - REAR
Service repair no - 70.55.03
Remove
1.Loosen rear road wheel nuts.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
3.Remove road wheel.
4.Remove split pins from brake pad retaining pins.
5.Remove brake pad retaining pins.
6.Remove brake pad retainer springs.
7.Remove brake pads and shim if fitted.
8.Position container beneath brake caliper to
collect spillage.
9.Loosen brake pipe union and disconnect from
caliper.
CAUTION: Plug the connections.
10.Remove 2 bolts securing caliper.
11.Remove brake caliper.
ProCarManuals.com

BRAKES
9
REPAIR Refit
12.Clean caliper to axle bracket mating faces.
13.Position caliper to axle bracket, fit bolts and
tighten to82 Nm (60 lbf.ft).
14.Remove plugs from pipe and caliper.
15.Clean brake pipe union and caliper.
16.Connect pipe to caliper, tighten union to15 Nm
(11 lbf.ft).
17.Apply a light film of grease to rear of brake pads.
18.Fit brake pads.
From 02MY, ensure shims are correctly fitted,
see illustration.
NOTE: Vehicles from 02MY have leading
and trailing edge chamfers on rear pads.
19.Fit pad retainer springs.
20.Fit brake pad retaining pins and secure with new
split pins.
21.Bleed brakes.See Adjustment.
22.Depress brake pedal to seat pads onto discs.
23.Fit road wheels, remove axle stands and tighten
nuts to130 Nm (96 lbf.ft).SWITCH - STOP LIGHT
Service repair no - 70.35.42
Remove
1.Disconnect 2 Lucars from stop light switch.
2.Remove mastic from around switch.
3.Remove switch from pedal box.
Refit
4.Fit and tighten switch to pedal box.
5.Apply mastic to switch.
6.Connect 2 Lucars to switch.
ProCarManuals.com

70BRAKES
10
REPAIR FRONT BRAKE PADS - FROM 02MY
Service repair no - 70.40.02
Remove
1.Remove front road wheels.
2.Clean exterior of calipers.
3.Remove split 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 clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads.
NOTE: Ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
9.Fit pad retaining pins and anti-rattle springs.
Secure with new split pins.
ProCarManuals.com

BRAKES
11
REPAIR 10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to130 Nm (96 lbf/ft).
12.Check fluid reservoir. Top up if necessary, using
correct grade of fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.REAR BRAKE PADS - FROM 02MY
Service repair no - 70.40.03
Remove
1.Remove rear road wheels.
2.Clean exterior of calipers.
90 Models
110/130 Models
3.Remove pad retaining pins and anti-rattle
springs. Note differences between 90 and
110/130 models.
4.Remove brake pads and shims.
ProCarManuals.com

70BRAKES
12
REPAIR 5.Clean exposed parts of pistons, using new brake
fluid.
6.Wipe away excess fluid with lint free cloth.
7.Using piston clampLRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8.Fit brake pads and shims.
Ensure shims are correctly fitted, see illustration.
NOTE: Vehicles from 02MY have leading
and trailing edge chamfers on rear pads.
Shims are also fitted.
9.Fit anti-rattle springs and secure with retaining
pins.10.Apply service brake pedal several times to locate
pads.
11.Fit road wheels, remove chassis stands and
jack. Tighten wheel nuts to130 Nm (96 lbf/ft).
12.Check fluid reservoir, top up if necessary, using
correct grade of fluid.See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
ProCarManuals.com

CHASSIS AND BODY
3
DESCRIPTION AND OPERATION The tail door for 02MY is completely redesigned to address manufacturing complexity, corrosion and water ingress
probelms on previous tail doors.
The tail door is now a one piece outer skin pressing located on a reinforced steel, zinc plated frame. This gives
improved build quality, water integrity and minimal welding.
A new tail door glass is introduced with a one piece continuous rubber seal. The tail door glass has a revised
Heated Rear Window (HRW) element on the glass which removes the need to route wires up the sides of the
frame. The HRW element now has integral Lucar connections in the element which provide the earth connections
for the new centre high mounted stop lamp.
The inner trim panel is new and accommodates the CDL actuator and linkages.
The new tail door also contains a relay for rear wiper motor operation. Refer to the Wipers section for details.
Because the new tail door uses the current hinges and latch and retains the same geometry as the previous tail
door, the new tail door assembly is available as a service item for current vehicles.
ProCarManuals.com