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.