Defender (1999-2002). Manual — part 90
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BRAKES
7
REPAIR
Refit
11. Position modulator to mounting bracket and
connect multiplug.
12. Fit modulator to mounting bracket and tighten
nuts to 9 Nm (7 lbf.ft) .
13. Connect 2 multiplugs to rear of modulator.
14. Remove plugs from brake pipes and modulator.
15. Clean brake pipe unions.
16. Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
17. Tighten all unions to 14 Nm (10 lbf.ft) .
18. Bleed brake system. See Adjustment.
NOTE: To ensure correct operation, the
ABS system MUST be tested using
TestBook.
BRAKE CALIPER - FRONT
Service repair no - 70.55.02
Remove
1. Loosen front road wheel nuts.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel.
4. Remove split pins from pad retaining pins.
5. Remove brake pad retainers and springs.
6. Remove brake pads and shim if fitted.
7. Pull back brake hose shield.
8. Clamp brake hose using a suitable clamp.
9. Position container beneath brake caliper to
collect spillage.
10. Loosen brake pipe union and disconnect from
caliper.
11. Plug brake pipe and caliper connections.
12. Remove 2 bolts securing caliper.
13. Remove brake caliper.
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70
BRAKES
8
REPAIR
Refit
14. Clean caliper to hub mating faces.
15. Position caliper to hub, fit bolts and tighten to 82
Nm (60 lbf.ft).
16. Remove plugs from pipe to caliper connections
and wipe.
17. Connect pipe to caliper, tighten union to 15 Nm
(11 lbf.ft).
18. Apply a light film of grease to rear of brake pads.
19. Fit pads to calipers.
From 02MY, ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
20. Fit pad retainers and springs.
21. Fit split pins to retainers.
22. Remove brake hose clamp.
23. Bleed brakes. See Adjustment.
24. Depress brake pedal to seat pads onto discs.
25. Fit road wheels, remove axle stands and tighten
nuts to 130 Nm (96 lbf.ft).
BRAKE CALIPER - REAR
Service repair no - 70.55.03
Remove
1. Loosen rear road wheel nuts.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel.
4. Remove split pins from brake pad retaining pins.
5. Remove brake pad retaining pins.
6. Remove brake pad retainer springs.
7. Remove brake pads and shim if fitted.
8. Position container beneath brake caliper to
collect spillage.
9. Loosen brake pipe union and disconnect from
caliper.
CAUTION: Plug the connections.
10. Remove 2 bolts securing caliper.
11. Remove brake caliper.
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BRAKES
9
REPAIR
Refit
12. Clean caliper to axle bracket mating faces.
13. Position caliper to axle bracket, fit bolts and
tighten to 82 Nm (60 lbf.ft).
14. Remove plugs from pipe and caliper.
15. Clean brake pipe union and caliper.
16. Connect pipe to caliper, tighten union to 15 Nm
(11 lbf.ft).
17. Apply a light film of grease to rear of brake pads.
18. Fit brake pads.
From 02MY, ensure shims are correctly fitted,
see illustration.
NOTE: Vehicles from 02MY have leading
and trailing edge chamfers on rear pads.
19. Fit pad retainer springs.
20. Fit brake pad retaining pins and secure with new
split pins.
21. Bleed brakes. See Adjustment.
22. Depress brake pedal to seat pads onto discs.
23. Fit road wheels, remove axle stands and tighten
nuts to 130 Nm (96 lbf.ft).
SWITCH - STOP LIGHT
Service repair no - 70.35.42
Remove
1. Disconnect 2 Lucars from stop light switch.
2. Remove mastic from around switch.
3. Remove switch from pedal box.
Refit
4. Fit and tighten switch to pedal box.
5. Apply mastic to switch.
6. Connect 2 Lucars to switch.
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70
BRAKES
10
REPAIR
FRONT BRAKE PADS - FROM 02MY
Service repair no - 70.40.02
Remove
1. Remove front road wheels.
2. Clean exterior of calipers.
3. Remove split pin from retaining pins.
4. Remove pad retaining pins and anti-rattle
springs.
5. Remove brake pads.
6. Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7. Using piston clamp LRT-70-500 press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8. Fit brake pads.
NOTE: Ensure pads are correctly fitted,
with leading edge chamfer fitted as shown.
9. Fit pad retaining pins and anti-rattle springs.
Secure with new split pins.
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