1999 LAND ROVER DEFENDER brake fluid

FRONT SUSPENSION
1
REPAIR PANHARD ROD - FROM 02MY
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to230 Nm (170 lbf/ft).BEARINGS - FRONT HUB
Service repair no - 60.25.14
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove front road wheel.
3.Pull back front brake caliper jump hose shield
and clamp brake hose.
4.Position container collect brake fluid.
5.Loosen brake pipe to jump hose union and
disconnect.
CAUTION: Use 2 spanners when loosening
or tightening unions.
6.Remove 2 bolts securing brake caliper to hub.
7.Remove brake caliper.
CAUTION: Plug the connections.
8.Remove dust cap.
9.Remove circlip and shim(s) from drive shaft.
10.Remove and discard 5 bolts securing driving
member to hub.
11.Remove driving member and discard gasket.
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64REAR SUSPENSION
2
REPAIR 25.If end float is present refer to table for correct
spacer and change spacer as necessary.
26.When no end float is evident, remove the dial
gauge and mounting bracket.
27.Stake the hub nut.
28.Clean hub and axle shaft faces.
29.Fit new driving member gasket.
30.Position driving member to hub and tighten new
bolts to65 Nm (48 lbf.ft).
31.Fit original shim(s) to drive shaft and secure with
circlip.
32.Position caliper to hub, fit bolts and tighten to82
Nm (61 lbf.ft).
33.Fit road wheel, remove axle stands and tighten
road wheel nuts to130 Nm (96 lbf.ft).
34.Operate brake pedal to locate brake pads before
driving vehicle.
35.Check and top up brake fluid.
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BRAKES
1
ADJUSTMENT BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.See this Section. general brake
service practice
During bleed procedure, brake fluid level must
not be allowed to fall below the MIN mark. Keep
reservoir topped up to the MAX mark.
To bleed the hydraulic circuits, four bleed
nipples are provided, one at each caliper.
There are two methods by which air can be removed
from the braking system:-
1.MANUAL BLEED PROCEDURE
2.PRESSURE BLEED PROCEDURE
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lb/in.
Manual bleed procedure
Equipment required
Clean glass receptacle
Bleed hose
Wrench
Approx. 2 litres (3 pts) brake fluid
Master cylinder bleed
1.Disconnect battery negative lead.
2.Depress brake pedal fully and slowly 5 times.
3.Release pedal and wait 10 seconds.
4.Repeat until firm resistance is felt at the pedal.Complete circuit bleed
1.Disconnect battery negative lead.
2.Fit bleed hose to caliper bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed nipple.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depresses, tighten bleed
nipple then release pedal.
7.Repeat procedure for remaining calipers.
8.Fit bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete.
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70BRAKES
4
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Remove
1.Disconnect battery negative lead.
2.Place a container under the master cylinder to
collect any brake 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.
3.Clean area around master cylinder ports.
4.Loosen 2 unions securing brake pipes to master
cylinder ports.
5.Disconnect both brake pipes from master
cylinder. Cover, not plug, pipe ends to prevent
entry of dirt.
6.Disconnect 2 Lucars from reservoir cap.
7.Remove 2 nuts securing master cylinder to
brake servo.
8.Withdraw master cylinder from servo and
remove.
Do not carry out further dismantling if
component is removed for access only.9.Carefully ease reservoir from master cylinder by
rolling it from seals.
10.Remove seals from master cylinder.
NOTE: Master cylinder to reservoir seals
are different sizes.
11.Fit NEW seals to master cylinder, ensuring seals
are fitted to correct ports.
12.Fit reservoir to master cylinder.
Refit
13.Ensuring that water ingress seal is in position, fit
master cylinder to servo.
14.Fit nuts securing master cylinder to servo and
tighten to26 Nm (19 lbf.ft).
15.Connect brake pipes to master cylinder and
tighten unions to15 Nm (11 lbf.ft).
16.Connect Lucars to reservoir cap.
17.Fill reservoir with recommended brake fluid.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
18.Bleed the brake system.See Adjustment.
19.Reconnect battery negative lead.
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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.
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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.
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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.
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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.
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