Defender 300Tdi (1996+). Manual — part 72
70
BRAKES
12
REPAIR
REAR BRAKE CALIPER ASSEMBLY
Key to rear caliper
1. Caliper
2. Bleed screw
3. Pad retaining springs
4. Brake pads
5. Piston
6. Wiper seal retainer
7. Wiper seal
8. Fluid seal
9. Retaining pins
BRAKES
13
REPAIR
REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Before starting repair refer to General brake service
practice
See General Brake Service Practice.
Remove caliper
1. Remove rear road wheels.
2. Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
90 Models
110/130 Models
3. Remove brake pipe from rear brake caliper.
4. Seal pipe ends to prevent ingress of dirt.
5. Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6. Remove 2 bolts and withdraw caliper from rear
axle.
Repair
WARNING: Do not separate caliper halves.
7. Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTION expel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9. Finally, remove pistons keeping them identified
with their respective bores.
10. Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and 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 particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.
13. Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14. Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.
70
BRAKES
14
REPAIR
REV: 09/97
15. Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16. Using special tool LRT-70-500 - piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17. Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18. Fit caliper to axle, tighten 2 bolts evenly to
82
Nm (60 lbf/ft).
19. Connect brake pipe to caliper. Tighten to
15 Nm
(11 lbf/ft).
20. Remove clamp from flexible brake hose.
21. Insert pads and retaining springs, secure in
position with new retaining pins and spread ends
or fit new split pins, depending on vehicle model.
Note correct position of retaining springs on 90
models.
22. Bleed brake system
See Brake System Bleed .
23. Press brake pedal firmly several times to locate
pads.
24. 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)
25. Road test vehicle. Note new brake pads require
’bedding-in’, for several hundred miles before
brakes are at maximum efficiency.
REAR BRAKE DISC
Service repair no - 70.10.11.
Remove
1. Remove rear hub assembly
See REAR AXLE
AND FINAL DRIVE, Repair, Rear hub
assembly .
2. Remove disc bolts.
3. Remove disc from rear hub.
Refit
4. Fit disc to rear hub.
5. Fit disc bolts. Tighten to
73 Nm (54 lbf/ft).
6. Check total disc run out, this must not exceed
0,15 mm (0.006 in). If necessary reposition disc.
7. Fit rear hub assembly
See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly .
Disc reclamation
8. Check disc thickness. This dimension may be
machined to minimum thickness of 12 mm.
Machine equal amounts off each face.
NOTE: The brake disc MUST BE renewed if
the minimum running thickness stamped
on the disc is recorded.
BRAKES
15
REPAIR
TRANSMISSION BRAKE
1. Pin
2. Washer
3. ’C’ clip
4. Brake shoe
5. Cable lever
6. Hold down spring
7. Dished washer
8. Brake drum
9. Screw
10. Brake cable
11. Adjuster slide
12. Aadjuster nut
13. Spring
14. Adjuster slide
15. Adjuster bolt
16. Dished washer
17. Hold down spring
18. Brake shoe
19. Hold down pin
20. Hold down pin
21. Abutment plate
22. Back plate
23. Spring
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