Range Rover Classic. Manual — part 125
BRAKES
7
REPAIR
19. Coat new seals in unused brake fluid. Fit ’L’ seal
to plunger.
20. Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
ASSEMBLING MASTER CYLINDER
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly. Never
use old fluid or any other form of cleaning and
lubricating material. Cleanliness throughout is
essential.
21. Fit new swirl tube to bottom of cylinder bore.
22. Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23. Fit new primary plunger assembly using same
method as for secondary plunger.
24. Fit original guide ring to support primary plunger.
25. Coat a new ’O’ ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
NOTE: DO NOT ROLL ’O’ ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. DO NOT OVER
STRETCH SEAL.
26. Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27. Fit two new reservoir seals in respective ports.
28. Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29. Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, DO
NOT ADJUST TRANSFER HOUSING AFTER
FITTING.
30. Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31. Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
70
BRAKES
8
REPAIR
Refit
32. Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33. Fit brake pipes to master cylinder. Tighten to
10Nm.
34. Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35. Bleed system.
See Brake System Bleed (Non
ABS)
WARNING: Do not use brake fluid
previously drained or bled from system.
Carefully dispose of unwanted fluid, if
stored in a sealed container, ensure that container
is marked USED BRAKE FLUID.
36. Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.
SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
NOTE: Other than replacing filter,
non-return valve and grommet, the servo
is not a serviceable component, in event of
failure or damage fit a new unit.
1. Disconnect battery negative lead.
2. Disconnect electrical plug to low fluid level
switch.
3. Thoroughly clean immediate area around all
master cylinder outlet ports. Remove each brake
pipe, sealing each pipe and outlet port with
suitable plugs to prevent ingress of foreign
matter.
4. Disconnect vacuum supply hose to servo.
5. Remove lower dash panel to gain access to
servo push rod.
6. Remove clevis pin securing servo push rod to
brake pedal.
7. Remove 2 nuts and plain washers securing
servo.
BRAKES
9
REPAIR
8. Remove servo and master cylinder assembly.
9. Drain brake fluid into a suitable container. (If
master cylinder is kept horizontal it is not
necessary to drain fluid).
WARNING: Do not use brake fluid
previously drained or bled from system.
Carefully dispose of unwanted fluid, if
stored in a sealed container, ensure that container
is marked USED BRAKE FLUID.
10. Detach spacer from pedal box mounting face of
servo.
NOTE: Retain spacer reassembly. The
spacer ensures stringent pedal to servo
operating dimensions are maintained.
11. Remove master cylinder from existing servo and
refit to new servo, if fitting new unit.
Refit
12. Fit spacer to servo.
13. Fit servo to pedal box.
14. Lightly grease brake pedal around area servo
push rod pivots.
15. Fit push rod to brake pedal. Fit clevis pin and
clip. Use lower hole.
16. Secure servo with two nuts and plain washers.
Tighten nuts to
24 Nm.
17. Refit lower dash panel.
18. Fit master cylinder to servo, refit nuts, plain and
spring washers. Tighten nuts to
26 Nm.
19. Remove all sealing plugs. Refit brake pipes to
respective ports. Tighten brake pipes to
10 Nm.
20. Refit vacuum supply hose.
21. Fill master cylinder to correct level using correct
grade of brake fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
22. Bleed brake system.
See Brake System Bleed
(non ABS)
70
BRAKES
10
REPAIR
FRONT BRAKE PADS
Service repair no - 70.40.02
Service tool:
LRT-70-500 - Piston clamp
Remove
Brake pad identification
Direction of rotation
From side of vehicle, looking through disc and caliper
at inboard pad, ’D’ shaped material on rear of inboard
pad should face direction of forward rotation of road
wheel with curved part of ’D’ always at trailing end of
caliper.
Brake pad wear sensed on RH calipers.
1. Remove front road wheels.
See WHEELS AND
TYRES, Repair, Wheels
2. Disconnect battery negative lead.
3. Disconnect pad wear sensor plug (front right
hand side only).
4. Clean exterior of calipers.
5. Remove split pins from retaining pins.
6. Remove pad retaining pins and anti-rattle
springs.
7. Remove brake pads.
8. Clean exposed parts of pistons, using new brake
fluid.
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