2002 LAND ROVER DISCOVERY ECU

BRAKES
70-26 DESCRIPTION AND OPERATION
Description
General
The handbrake consists of a drum brake, installed on the rear of the transfer box, operated by a cable connected to
a handbrake lever between the front seats.
Handbrake lever
The handbrake lever is mounted on a base plate which attaches to the transmission tunnel. A conventional ratchet
and thumb operated release button are incorporated for locking and unlocking the lever. A warning switch on the base
of the lever operates the brake warning lamp in the instrument pack. While the handbrake is applied the warning
switch connects an earth to the instrument pack which, if the ignition is on, illuminates the brake warning lamp. In
some markets, the instrument pack performs a bulb check of the brake warning lamp each time the ignition is switched
on.
Cable
The handbrake cable consists of inner and outer cables installed between the handbrake lever and the drum brake.
A protective sleeve is installed on the cable to protect the cable from heat from the exhaust system. Handbrake
adjustment is provided by a threaded sleeve installed on the outer cable where it locates in the handbrake lever.
Turning an adjuster wheel, which is keyed to the threaded sleeve and secured by a 'C' clip, alters the effective length
of the outer sleeve and consequently changes the handbrake lever movement needed to apply the drum brake.

BRAKES
DESCRIPTION AND OPERATION 70-27
Drum brake
1Drum
2Drum securing bolt
3Backplate
4Cable
5Backplate securing bolt
The drum brake consists of a backplate attached to the transfer box casing and a drum attached to the transfer box
rear output shaft. When the handbrake lever is applied, the movement is transmitted by the inner cable to a lever on
one of the brake shoes on the backplate. The lever pivots against the brake adjuster rod, which forces the shoes apart
and into contact with the drum. Brake shoe to drum clearance is set by an adjusting bolt on the rear of the backplate.

BRAKES
ADJUSTMENTS 70-29
ADJUST ME NTS
Handbrake
$% 70.45.09
Check
1.Apply the handbrake lever 3 notches on the
ratchet. The handbrake should be fully
operational.
2.If the handbrake is not fully operational, the
brake shoes and/or the handbrake cable need
adjusting.
Adjust
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Ensure handbrake lever is fully released.
3.Tighten brake shoe adjusting bolt until brake
drum is locked, then back off adjusting bolt 1.5
turns. Check that the brake drum is free to
rotate.
4.Recheck handbrake operation.If handbrake is
not fully applied with 3 notches on the
ratchet, the handbrake cable requires
adjustment.
5.Remove switch panel from centre console.

+ WINDOWS, REPAIRS, Switch -
console.
6.Release handbrake lever gaiter from centre
console.7.Rotate adjuster anti-clockwise to increase
cable tension (reduce notches) or clockwise to
decrease cable tension (increase notches).
8.Recheck handbrake operation.
9.Secure handbrake lever gaiter to centre
console.
10.Fit switch panel to centre console.

+ WINDOWS, REPAIRS, Switch -
console.
11.Remove stand(s) and lower vehicle.

BRAKES
REPAIRS 70-33
REPAIRS
Brake disc - front
$% 70.12.10
Brake discs must be renewed in pairs, unless
one disc requires changing before 1000 miles
(1500 km) from new.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Remove 2 bolts securing brake caliper to
swivel hub.
4.Release caliper and tie aside clear of brake
disc.
CAUTION: Do not allow caliper to hang on
brake hose.
5.Remove screw securing disc to drive flange.
6.Remove brake disc from drive flange Refit
1.Clean mating faces of drive flange and new
disc.
2.Fit brake disc to drive flange, fit screw and
tighten to 13 Nm (10 lbf.ft).
3.Clean mating faces of caliper and hub.
4.Fit caliper, and tighten bolts to 175 Nm (129
lbf.ft).
5.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
6.Remove stand(s) and lower vehicle.

BRAKES
70-34 REPAIRS
Brake disc - rear
$% 70.12.33
Brake discs must be renewed in pairs, unless
one disc requires changing before 1000 miles
(1500 km) from new.
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Remove 2 bolts securing brake caliper to rear
hub.
4.Release caliper and tie aside clear of brake
disc.
CAUTION: Do not allow caliper to hang on
brake hose.
5.Remove screw securing disc to drive flange.
6.Remove brake disc from drive flange. Refit
1.Clean mating faces of drive flange and new
disc.
2.Fit brake disc to drive flange, fit screw and
tighten to 13 Nm (10 lbf.ft).
3.Clean mating faces of caliper and hub.
4.Fit caliper and tighten bolts to 95 Nm (70 lbf.ft).
5.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
6.Remove stand(s) and lower vehicle.

BRAKES
REPAIRS 70-35
Master cylinder - brake
$% 70.30.08
Remove
1.Disconnect multiplug from fluid level switch.
2.Position cloth under master cylinder to absorb
spilled fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
3.Disconnect secondary system pipe union from
master cylinder.
4.Disconnect primary system pipe union from
master cylinder.
5. Manual gearbox only: Release clip and
disconnect clutch fluid supply hose from
reservoir.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 2 nuts and washers securing master
cylinder to servo.
7.Remove master cylinder. Refit
1.Clean master cylinder and servo mating
surfaces.
2.Align push rod and position master cylinder to
servo.
3.Fit nuts and washers securing master cylinder
to servo and tighten to 25 Nm (18 lbf.ft).
4.Connect primary and secondary brake pipes,
and tighten unions to 25 Nm (18 lbf.ft).
5. Manual gearbox only: Connect clutch fluid
hose to reservoir, secure with clip.
6.Connect fluid level switch multiplug.
7.Bleed brake system using TestBook/T4.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.

BRAKES
70-36 REPAIRS
Cable - handbrake
$% 70.35.25
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Remove clip and clevis pin securing cable to
hand brake lever.
3.Remove brake shoes from hand brake
assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.From below the vehicle, pull handbrake cable
through transmission tunnel.
5.Release handbrake cable from backplate. Refit
1.Fit and secure handbrake cable to backplate.
2.Position hand brake cable through
transmission tunnel.
3.Fit brake shoes to hand brake assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.Align cable to hand brake lever and secure with
clip and clevis pin.
5.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
6.Adjust handbrake.

+ BRAKES, ADJUSTMENTS,
Handbrake.

BRAKES
REPAIRS 70-37
Switch - brake light
$% 70.35.42
The brake switch is set automatically during fitment.
If the setting is disturbed, the switch can be reset by
depressing the brake pedal and pulling the plunger
out of the switch body, until it contacts the pedal.
Remove
1.Remove 3 fasteners and move drivers side
lower closing panel aside.
2.Disconnect multiplug from brake light switch.
3.Remove brake light switch from pedal bracket.
Refit
1.Engage switch fully into pedal bracket location
and connect multiplug.
2.Position lower closing panel and secure with
fasteners.
Brake pads - front
$% 70.40.02
WARNING: Brake pads must be renewed in axle
sets only, otherwise braking efficiency may be
impaired.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Remove lower guide pin bolt from caliper and
pivot caliper housing upwards.
4.Remove 2 brake pads from caliper carrier.
Shims are part of the brake pads.
Refit
1.Rotate disc by hand and scrape all scale and
rust from around edge of disc.
2.Scrape rust from pad locating surfaces on
caliper.
3.Clean dust from calipers using brake cleaning
fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.