Land Rover Defender: Brake Pads 2 Piston Floating Caliper

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

206-080

Brake caliper piston retractor tool

MATERIALS

GENERAL EQUIPMENT

REMOVAL

WARNINGS:

• Brake pads must be renewed in axle sets only. Failure to follow this instruction may result in braking efficiency being impaired.
• If the brake pad wear warning indicator has been activated, a new brake pad wear sensor must be installed.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Use the Jaguar Land Rover (JLR) approved diagnostic equipment to activate the Integrated Power Brake assembly mode.

General Equipment: Jaguar Land Rover approved diagnostic equipment

2. Raise and support the vehicle on a suitable 2 post lift.

3. Remove the wheel and tire.

4.

CAUTION: The brake pad wear sensor is easily damaged. Do not use a lever to remove the sensor. Use fingers only.

NOTE: Left side only.

• Disconnect the brake pad wear sensor.
• Release the brake pad wear sensor grommet and position the component to one side.

5.

• Remove the 2 brake caliper slide pins.
• Release the brake caliper and position to one side.

  General Equipment: Cable ties

6.

NOTE: Note the orientation of the brake pads prior to removal.

Remove the 2 brake pads.

7. Repeat the above steps for the other side.

INSTALLATION

1.

WARNING: Do not use compressed air to clean brake components. Dust from friction materials can be harmful if inhaled.

Use brake cleaner fluid to clean the brake caliper housing and brake caliper carrier.

Material: Brake Cleaner (3U7J-2C410-AA)

2.

CAUTION:

As the piston is pushed back into the caliper housing, the brake fluid level in the reservoir will rise.

Check the brake fluid reservoir level before pushing the piston back, failure to follow this instruction may result in damage to the vehicle.

• Inspect the caliper piston, slide pin seals and brake pad contact points for damage.
• Use the special tool to press the 2 brake caliper pistons into the brake caliper housing.

  Special Tool(s): 206-080

3.

CAUTION: Make sure the brake pads are installed in the correct orientation.

• Install the anti-rattle spring.
• Install the brake pads.

4.

Install and tighten the 2 brake caliper slide pins.

Torque: 35Nm

5. Repeat the above procedure for the other side.

6.

NOTE: Left side only.

• Connect the brake pad wear sensor to the brake pad.
• Secure the brake pad wear sensor grommet.

7. Install the wheels and tires.

8.

CAUTION: Failure to follow this instruction may lead to brake warning lamps and Diagnostic Trouble Code(s) (DTC) being set.

1. NOTE: Although the brake pedal might feel firm make sure to hold the pedal through the 10 second period.

If the Integrated Power Brake unit - 'Assembly Mode' has not been activated, press and hold the brake pedal in a single apply for 10 seconds.

2. If the brake pedal felt soft and fell to the floor proceed to substep 4.
3. If the brake pedal felt firm proceed to substep 5.
4. NOTE: Make sure to repeatedly press the brake pedal until a firm brake pedal feel is reached.

If the Integrated Power Brake unit - 'Assembly Mode' has been activated, press the brake pedal several times until a firm brake pedal feel is reached.

5. Check the fluid level in the brake fluid reservoir and top-up with brake fluid if necessary.

9. Use the JLR approved diagnostic equipment to deactivate the Integrated Power Brake assembly mode.

General Equipment: Jaguar Land Rover approved diagnostic equipment

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