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Defender 90 / 110 / 130. Manual - part 120

KING SYSTE

Remove and overhaul expander assembly

7. Remove the rubber dust cover.

Remove the expander and draw link.

9. Remove the retainer spring plate.

10. Remove the locking plate.
11. Remove the packing plate and withdraw the

12. Remove the two plungers and rollers.

13.

Clean all parts in Girling cleaning fluid and allow to
dry. Examine the components for wear and discard

if unsatisfactory.

expander assembly from the back-plate.

Assemble expander assembly

14. Grease and fit the expander and drawlink.
15. Grease and fit the plungers and rollers noting that

the highest end

the ramp on the plungers is fitted

towards the back-plate. Secure the assembly with a
rubber band to prevent the plungers falling out and

place

to one side for assembly to back-plate.

Remove and overhaul adjuster assembly

16. Remove the two bolts and withdraw the adjuster

17. Remove the plungers.
18. Screw the adjuster cone inwards to remove from

19. Clean the parts in Girling cleaning fluid and discard

assembly from the back-plate.

t h e

any unsatisfactory components.

Assemble adjuster assembly

20. Grease and screw in

the

adjuster cone.

21. Grease and fit the adjuster plungers and align the

chamfered ends with the adjuster cone. Note that
the two plungers are identical and can be fitted

either bore. Secure the assembly with a rubber
band to prevent the plungers falling out.

ASSEMBLE

NOTE: If the brake linings are oil-soaked check and if
necessary renew the output shaft oil seal.

22. Position the expander assembly on the inside of the

back-plate and secure with the following plates at
the rear

of the back-plate.

23. Packing piece.

Locking plate.

25. Retainer spring.
26.

Fit the rubber dust cover.

continued

...

KING S

YSTEM

27. Fit the adjuster assembly to the back-plate with the

two bolts but do not fully tighten at this stage.

28. Fit the back-plate assembly and mud shield to the

transfer box with the four bolts and tighten to the
correct torque.

29.

Fit new pull-off springs to relined brake shoes and
fit

to the back-plate. Note that the fully lined end

of the lower shoe must be toward the expander
assembly and the fully lined end

of the upper shoe

towards the adjuster assembly.

30. Fit the brake drum and secure with the two screws.
31. Connect the expander drawlink to the actuating

lever with a new clevis pin, washer and split pin.

32. Turn t h e adjuster cone fully in and tighten the two

retaining bolts

left

slack in instruction 27.

33. Slacken off the adjuster two ‘clicks’ and firmly

apply the hand lever to centralise the shoes. The
drum should

rotate freely.

34. Adjust the handbrake cable

t o

give the pawl two

‘clicks’ free movement on the ratchet before the
third ‘click’ fully expands the shoes against the
drum.

35. Connect the propeller shaft and evenly tighten the

retaining

to the correct torque.

Remove chocks from wheels and connect the

battery.

BLEEDING

THE BRAKES

Primed System

Bleed the front brakes first starting with the wheel
nearest to the master cylinder.
1. Attach a rubber tube to the bleed screw and

immerse the other end

a glass jar containing a

quantity of clean, new recommended brake fluid.

2. Check that the fluid reservoir is full to

the maximum

mark.

3 . Unscrew the bleed screw approximately half-a-turn,

enough to allow fluid to be pumped out.

Do not

open the screw too far o r air will be drawn back into
the system around the threads.

Smartly depress the foot pedal, pause and then
allow the pedal to rapidly return, pause again before
repeating the procedure.

5 .

Continue with the above sequence until all air

bubbles cease whilst ensuring that the reservoir is
kept topped-up.

6. Close the bleed screw immediately after the last

down stroke, whilst t h e

is depressed.

Unprimed System

bleed a replacement master cylinder or a fully

drained system.
7. Top up the

reservoir to the maximum mark.

Open a bleed screw in both circuits and allow fluid

to prime both circuits of the

cylinder by

gravity for approximately five minutes, then bleed
as for a primed system.

RAKING SYSTE

Secure the master cylinder

in a vice and push

primary plunger down the bore and withdraw the
secondary plunger stop pin.

OVERHAUL THE MASTER CYLINDER

1. Remove the master cylinder from the servo and

vehicle.

continued

2. Remove the master cylinder filler cap and pour

off

3 .

From the filler cap, prise out the plastic baffle and

Drive out the two roll pins and remove the

Prise out from the master cylinder the two

surplus fluid.

rubber seal.

reservoir from the master cylinder.

reservoir retaining seals.

KEY TO MASTER CYLINDER

1. Reservoir.

2. Reservoir filler cap.

-3. Rubber seal.

Plastic baffle.

Roll pins.

6 .

Reservoir retaining seals.

7. Secondary plunger stop pin.

Plastic circlip

9. Primary plunger assembly.

Secondary plunger assembly.

11. Master cylinder flange seal.
12.

Nuts and washers securing cylinder to servo.

‘8

BRAKING SYSTEM

Press down the primary plunger and remove the

Withdraw the primary plunger assembly.

plastic circlip.

9. Tap the master cylinder sharply on a soft or

wooden surface to remove the secondary plunger
assembly.

Fit a new outer seal into its groove by squeezing the

seal  between  the  finger and  thumb into an  ellipse
and press the raised  part of  the seal over the flange
using  the  fingers  of  the  other  hand.  Using  the
method illustrated for

the secondary

following instruction

16.

13. Fit the recuperating seal assembly parts in the

reverse order of removal. Compress the spring and
secure the assembly with the bolt tightening to 2 to
3

(1.5 to 2.2 Ibf ft).

Do not overtighten.

continued

....

Renewing primary plunger seals

10. Using a

2.5

key, unscrew the retaining

(a) spring retainer
(b) plunger spring
(c) seal retainer
(d) recuperating seal
(e) washer

the outer seal.

11. Taking care not to damage the plunger, prise off

Content .. 118 119 120 121 ..