Discovery I (LJ) V8-3.9L (1994)
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NOTE: Do not separate caliper halves
Repair
7. Clean outer surfaces of caliper using aerosol brake cleaner.
8. Using special tool LRT-70-500 or equivalent, clamp pistons in inboard half of caliper. Gently, keeping fingers clear, and with CAUTION, apply
air pressure to fluid inlet port to expel pistons. It is unlikely that pistons will expel at same time, regulate rate with a suitable piece of wood
between appropriate piston and caliper.
9. Finally remove pistons, identifying them with their respective bores.
10. Remove wiper seal retainer by inserting a blunt screwdriver between retainer and seal. 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 seal grooves using clean brake fluid only. If caliper or pistons are corroded, or their condition is not perfect, new parts
must be fitted.
Assemble pistons
13. Coat new fluid seal with brake fluid. Ease seal into groove in bore using only fingers, ensuring it is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels raised to touch at edge furthest away from mouth of bore.
14. Coat appropriate piston with brake fluid. Insert it squarely into bore by hand only. Do not tilt piston during insertion, leave approximately 8mm
projecting from bore.
15. Coat new wiper seal with brake fluid and fit to new seal retainer.
16. Slide assembly, seal first, over protruding piston and into bore recess. Use piston clamp to press home seal retainer and piston.
REFIT
1. Fit caliper, tighten bolts evenly to 82 Nm (61 ft lb).
2. Connect brake flexible hoses to caliper. Tighten to 15 Nm (12 ft lb).
3. Remove hose clamps.
4. Insert pads. Fit pins and springs, secure using new split [cotter] pin.
5. Bleed brake system.
6. Press brake pedal firmly several times to locate friction pads.
7. Fit road wheels, remove axle stands. Finally tighten road wheel nuts.
7. Road test vehicle.
NOTE: that new friction pads require bedding-in. This may take several hundred miles before brakes are at maximum efficiency.
