300Tdi Discovery
BRAKES
13
REPAIR
FRONT BRAKE CALIPERS
Service repair no - 70.55.03
Service repair no - 70.55.16
Service tool:
LRT-70-500 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1. Loosen front wheel retaining nuts, raise front of
vehicle, lower onto axle stands, remove wheels.
2. Expose flexible brake hose by moving coiled
protective covering.
3. Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4. Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5. Remove split [cotter] pin, retaining pins and
springs, withdraw pads. If refitting pads, identify
them for assembly to original locations.
6. Loosen bolts and remove caliper.
Repair
Do not separate caliper halves
7. Clean outer surfaces of caliper using aerosol
brake cleaner.
8. Using special tool LRT-70-500, 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.
