Discovery 2. Manual — part 216

BRAKES

REPAIRS

70-39

Brake pads - rear

$% 70.40.10

WARNING: Brake pads must be renewed in axle
sets only, otherwise braking efficiency may be
impaired.

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 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.

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.

BRAKES

70-40

REPAIRS

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.

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.

BRAKES

REPAIRS

70-41

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

70-42

REPAIRS

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.