Discovery 2. Manual — part 637

BRAKES

REPAIRS

70-39

4. Using tool LRT-70-500, press caliper pistons

fully into bores. Ensure that displaced fluid
does not overflow from reservoir.

5. Fit pads to caliper carrier.
6. Lower caliper housing over pads.
7. Ensure flats on guide pins locate with lugs on

caliper housing. fit new pivot bolt and tighten to
30 Nm (22 lbf.ft).

8. Fit road wheel(s) and tighten nuts to 140 Nm

(103 lbf.ft).

9. Remove stand(s) and lower vehicle.

10. Depress brake several times to set pad to disc

clearance.

11. Check and top-up brake fluid.

Brake shoes - handbrake

$% 70.45.18

Remove

1. Remove rear propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

2. Remove screw and remove brake drum.

BRAKES

70-40

REPAIRS

3. Remove 2 washers, springs and pins retaining

brake shoes to back plate.

4. Release return springs and remove brake

shoe.

5. Remove retaining spring securing abutment

lever to back plate.

6. Release remaining brake shoe from brake

cable, remove brake shoe and collect return
springs.

7. Remove adjuster plungers.
8. Remove 'C' clip securing cable lever to brake

shoe. Remove flat washer, lever, 2 Belleville
washers and pivot pin.

Refit

1. Clean components with brake cleaning fluid.

WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.

2. Lubricate cable lever pivot pin.
3. Fit pivot pin to shoe, fit cable lever washers and

secure with 'C' clip.

4. Fit adjuster plungers.
5. Fit shoe to brake cable, align to back plate and

adjuster. Secure shoe to back plate with pin,
spring and washer.

6. Fit abutment plate to brake shoe.
7. Fit return springs with remaining shoe. Secure

shoe to back plate with pin, spring and washer.

8. Fit abutment plate retaining spring.
9. Clean brake drum and mating face.

10. Position brake drum and tighten retaining

screw.

11. Fit rear propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

12. Adjust handbrake.

+

BRAKES, ADJUSTMENTS,

Handbrake.

BRAKES

REPAIRS

70-41

Servo - brake

$% 70.50.01

Remove

1. Remove brake master cylinder.

+

BRAKES, REPAIRS, Master cylinder

- brake.

2. Disconnect vacuum pipe from servo.

3. Release spring clip securing servo push-rod to

brake pedal and release pedal.

4. Remove 2 flanged nuts securing servo to

bulkhead.

5. Remove brake servo.

Refit

1. Clean servo and mating faces,
2. Position servo and tighten nuts to 25 Nm (18

lbf. ft).

3. Position brake pedal to servo push-rod and

secure with spring clip.

4. Connect vacuum pipe to servo.
5. Fit brake master cylinder.

+

BRAKES, REPAIRS, Master cylinder

- brake.

BRAKES

70-42

REPAIRS

Vacuum pump - servo

$% 70.50.19

Remove

1. Remove auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

2. Release cover and remove nut securing lead

to alternator.

3. Disconnect alternator multiplug.

4. Remove bolt (LH thread) and remove auxiliary

drive belt tensioner.

5. Remove bolt securing support stay to

alternator.

6. Release clip and disconnect oil drain hose from

vacuum pump.

7. Disconnect vacuum pump oil supply pipe from

cylinder head and discard 'O' ring.

8. Remove bolt securing alternator and release

from mounting bracket.

9. Disconnect vacuum hose from vacuum pump.

10. Remove alternator. Take care not to damage

radiator cooling fins.

11. Remove 4 bolts, and remove vacuum pump

from alternator.

CAUTION: Always fit plugs to open
connections to prevent contamination.