Defender 300Tdi (1996+). Instruction - page 71

70

BRAKES

8

REPAIR

REV: 09/97

REAR BRAKE PADS

Service repair no - 70.40.03

Service tool:

Remove

1. Remove rear road wheels.
2. Clean exterior of calipers.
3. Remove pad retaining pins and anti-rattle

springs. Note differences between 90 and
110/130 models.

4. Remove brake pads.
5. Clean exposed parts of pistons, using new brake

fluid. Wipe away excess with a lint free cloth.

6. Using piston clamp LRT-70-500 press each

piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.

Refit

7. Insert brake pads.
8. Fit anti-rattle springs and secure with retaining

pins.

9. Apply service brake pedal several times to locate

pads.

10. Fit road wheels, remove chassis stands and

jack. Tighten 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)

11. Check fluid reservoir, top up if necessary, using

correct grade of fluid

See LUBRICANTS,

FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
.

90 Models

110/130 Models

BRAKES

9

REPAIR

FRONT BRAKE CALIPER ASSEMBLY

Key to caliper

1. Caliper
2. Bleedscrew
3. Anti-rattle springs
4. Pad retaining pins
5. Split pin
6. Friction pads

7. Piston
8. Wiper seal retainer
9. Wiper seal

10. Fluid seal
11. Brake disc

70

BRAKES

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 tool LRT-70-500, clamp pistons in

inboard half of caliper. Gently, keeping fingers
clear, and with CAUTION, 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

11

REPAIR

REV: 09/97

Assemble outboard pistons

13. Coat new fluid seal with brake fluid. Ease seal

into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.

14. Coat appropriate piston with brake fluid. Insert it

squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.

15. Coat new wiper seal with brake fluid and fit to

new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.

Mounting inboard pistons

16. Clamp outboard pistons and carry out same

procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.

Fit calipers and pads

17. Fit caliper, tighten bolts evenly to

82 Nm (60

lbf/ft).

18. Connect brake flexible hoses to caliper. Tighten

to

15 Nm (11 lbf/ft).

19. Remove hose clamps.
20. Insert pads. Fit pins and springs, secure using

new split pin.

21. Bleed brake system

See Brake System Bleed

.

22. Press brake pedal firmly several times to locate

friction pads.

23. Fit road wheels, remove axle stands. Finally

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)

24. Road test vehicle. Note that new friction pads

require ’bedding-in’, this may take several
hundred miles before brakes are at maximum
efficiency.

FRONT BRAKE DISCS

Service repair no - 70.10.10.

Remove

1. Remove hub assembly

See FRONT AXLE AND

FINAL DRIVE, Repair, Front hub assembly .

2. Remove 5 hub to disc bolts.
3. Tap disc to separate from hub.

NOTE: On 110/130 vehicles ventilated
discs are fitted as standard.

Refit

4. Locate disc to hub.
5. Apply Loctite 270 to disc bolts and tighten to

73

Nm (54 lbf/ft).

6. Check total disc runout with a dial indicator, this

must not exceed 0,15 mm, 0.006 in. If necessary
reposition disc.

7. Fit hub assembly

See FRONT AXLE AND

FINAL DRIVE, Repair, Front hub assembly .

Disc reclamation

8. Check disc thickness. This dimension may be

machined to minimum thickness of 12 mm (0.47
in.) - solid discs, 22 mm (0.90 in) - ventilated
discs. Machine equal amount off each face.

NOTE: The disc MUST BE renewed if the
minimum running thickness stamped on
the disc is recorded.

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