Range Rover Classic
70
BRAKES
16
REPAIR
DISMANTLE AND REPAIR
CAUTION: Do not separate caliper halves.
Overhaul both calipers
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. Assemble
outboard pistons.
13. Coat a new fluid seal using brake fluid. Ease
seal into groove in bore using only fingers and
ensure that it is properly seated. The fluid seal
and groove are not same in section so that 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 and leave approximately 8mm
projecting from bore.
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 two bolts progressively
to
82Nm.
19. Connect brake pipe to caliper. Tighten to
12Nm.
Remove clamp from flexible brake hose.
20. Lightly coat back and edges of pads using brake
fluid, avoid friction material.
21. Insert pads and retaining springs, secure in
position with new retaining pins and spread
ends. Note correct position of retaining springs.
NOTE: Ensure pad with wear indicator is
fitted to inboard side of rear RH brake
caliper. New brake pads must be fitted to
each caliper.
22. Reconnect pad wear indicator electrical plug.
23. Bleed secondary brake system at rear calipers,
starting at caliper furthest away from master
cylinder.
24. Press brake pedal firmly several times to locate
pads.
25. Fit road wheels, remove axle stands and finally
tighten road wheel nuts,
26. Road test vehicle. Note new brake pads require
’bedding-in’, for several hundred miles before
brakes are at maximum efficiency.
