Disc Land Rover Range Rover III

INTRODUCTION

All vehicles covered in this article have Anti-Lock Brake System (ABS) as standard equipment. This article contains information on repair and service of non-ABS portion of the brake system. For servicing and diagnosing ABS portion of the brake system, see appropriate ANTI-LOCK article.

DESCRIPTION & OPERATION

The brake system is a dual circuit type with Electronic Brake Force (EBD) distribution through Dynamic Stability Control/Anti-lock Brake System (DSC/ABS) control. The mechanical brake system comprises

1. Vacuum booster. (Scheme 1)
2. Tandem master cylinder with two central valves for DSC operation.
3. Brake fluid reservoir with reed contact fluid level switch.
4. Vented front discs/Solid rear discs.
5. Single piston calipers.
6. Hydraulic lines. (Scheme 2)

Scheme 1

Scheme 2

The front brakes each comprise a hub mounted, single piston caliper assembly and a vented disc. The inboard side of the disc is protected by a mud shield. When hydraulic pressure is supplied to the caliper, the piston extends and forces the inner pad against the disc. The caliper body reacts and slides on the guide pins to bring the outer pad into contact with the disc.

The rear brakes each comprise a hub mounted, single piston caliper assembly and a solid disc. The operation is the same as for the front brakes. Both the left front inboard and right rear inboard brake pad wear is monitored by a sensor attached to the pad by a fly lead. If the brake pad warning has been triggered the sensor and brake pads must be replaced.

The parking brake lever is a clenched two-shell construction incorporating an automatic cable adjuster. (Scheme 3) The parking brake cables are actuated via an equalizer and a cable centrally mounted within the lever, which is in turn attached to one half of the spring loaded adjuster. The design of this hand brake incorporates an automatic adjuster which eliminates the need for adjustment. The two-shell design allows automatic assembly of the internal components. The hand brake cable is centrally mounted within the lever as a significant offset of the cable causes the lever to rotate sideways under the high cable loads required. This construction means that the part of the bracket that supports the lever pivot must be moved outside the lever rather than having the conventional inboard position. The lever is high mounted to suit the COMMAND driving position, on a secondary mounting bracket, which also allows the assembly of necessary components under the parking brake.

Scheme 3

When the lever is in the rest position, the adjuster opener holds the adjuster open. In this position, the lever is effectively disconnected from the parking brake cable. This allows the adjuster spring, if required, to remove slack in the parking brake cables. After less than 5 degrees of lever travel and normally before the first tooth is engaged, the adjuster is closed and the cables and hence the parking brakes are actuated. No adjustment of the cables is required during assembly. The function of the adjuster is to remove slack in the parking brake cables and not to provide any adjustment of the parking brake itself. The adjuster spring force is always lower than the brake shoe return spring force.

In order to achieve the required performance targets, the lever ratio is relatively high at 7.25:1. Fine ratchet teeth are employed for the convenience of slighter drivers. The overall performance of the system is totally dependent on the correct adjustment and bedding of the Duo-Servo parking brake. The adjuster travel is 0.98-1.18" (25-30 mm), in other words in the worst tolerance condition the system can compensate for is 0.98" (25 mm) of slack in the cable system. Slack in the system can be caused by both initial tolerance stack up in the body/parking brake system and actual stretch in the system.

The parking brake is supplied with a pin in position that locks the adjuster spring in the fully compressed condition. This allows the parking brake to be raised to the fully up position with the cables connected, in order to facilitate the assembly of the center console. Subsequent to the assembly of the center console, the pin can be removed and the lever lowered, at which point the adjuster will provide the required cable tension. A mounting clip is provided, which is clipped to the equalizer and fitted over the ends of the body tubes, in order to provide location while the cables are fed through the body tubes and into the quick fit connections in the equalizer. This allows a one man operation for cable installation.

BLEEDING BRAKE SYSTEM

Note. Following procedure covers partial bleeding of the system. Bleeding could be performed where only the primary or secondary circuit have been disturbed in isolation. It should only be necessary to bleed the disturbed system. This partial bleeding of the hydraulic system is only permissible if a brake pipe or hose has been disconnected with only minor loss of fluid.

Note. Ensure fluid in reservoir is maintained between MIN and MAX levels and new brake fluid is used throughout the bleeding procedure.

1. Raise and support vehicle. Ensure that all lines and connections are tight and no leaks are present. Fill brake fluid reservoir to MAX level with NEW DOT 4 brake fluid. Obtain a clean transparent bottle containing a small amount of clean brake fluid and a bleed hose. Go to next step.
2. Attach bleed hose to the first brake caliper bleed screw in sequence. (Scheme 4) Ensure free end of hose is submerged in the clean brake fluid. Apply pressure to brake pedal several times, then apply steady pressure. Loosen bleed screw to release brake fluid and air. Allow pedal to return unassisted. Go to next step.
3. Depress brake pedal steadily through its full stoke and allow to return unassisted. Repeat procedure until a flow of clean, air-free fluid is purged into container. Then while holding pedal at end of its downward stroke, tighten bleed screw to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Fill brake fluid reservoir to MAX level with NEW DOT 4 brake fluid.
4. Repeat procedure for the other 3 brake calipers in sequence. (Scheme 4)
5. Remove tube from bleed screw and install bleed screw dust cap. Apply brakes and check for leakage. Road test vehicle. Check brake pedal for short firm travel when brakes are applied.

Scheme 4

BRAKELIGHT SWITCH

Brakelight switch is automatically set during installation of the switch. If the setting is disturbed, brakelight switch may be readjusted by depressing brake pedal and pulling plunger out of brakelight switch body until it contacts pedal. Release brake pedal.

MASTER CYLINDER PUSH ROD

Note. Master cylinder push rod is not adjustable.

BEDDING PARKING BRAKE SHOES

1. To ensure parking brake shoes are properly seated in drums (bedded), first ensure parking brake is properly adjusted. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) .
2. Once parking brake is properly adjusted, drive vehicle at about 24 MPH and apply parking brake until braking force can be felt. Apply parking brake one further notch and drive vehicle for 440 yards (402 meters). Release parking brake.

PARKING BRAKE

1. Raise and support vehicle. Remove rear wheels. Remove adjuster access plug from brake disc. (Scheme 5) Rotate brake disc until access hole is in 6 O'clock position.
2. Using a screwdriver or similar tool, turn brake shoe adjuster until resistance is felt. Apply parking brake several times to center shoes, readjust if required and repeat.
3. Ensure parking brake is released and ensure that the disc will not rotate. Back adjuster off 8 notches, ensuring that the disc is free to rotate.
4. Install adjuster access plugs. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Parking brake lever assembly is self adjusting and will correctly tension cables. However, after adjustment apply parking brake several times, release parking brake and ensure rear wheels are free to rotate.

Scheme 5

SERVICING

Manufacturer specifies replacing brake fluid every 3 years or 45,000 miles, whichever is sooner using DOT 4 brake fluid. After replacing brake fluid, bleed brake system. See BLEEDING BRAKE SYSTEM . Manufacturer specifies replacing all brake seals and flexible hoses every 90,000 miles or 6 years, whichever is sooner.

Before disconnecting the battery, disable the alarm system and switch off all electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated. The ground lead must be disconnected first and reconnected last. Ensure battery leads are routed correctly and are not close to any potential chafing points.

Removal

1. Remove some brake fluid from brake fluid reservoir to prevent overflow. Raise and support vehicle. Remove front wheels. On left side, remove pad wear sensor. Remove anti-rattle spring from caliper housing. (Scheme 6) Remove 2 caps from guide pin dust covers.
2. Remove 2 guide pins from caliper housing. Release caliper housing from caliper carrier and tie aside. DO NOT allow caliper to hang on brake hose. If pads are to be reused, mark their location for reassembly. Remove brake pads from caliper. (Scheme 7)

Scheme 6

Scheme 7

Installation

1. Clean caliper housing and caliper carrier using brake cleaning fluid. Clean brake pad, caliper housing and carrier contact areas and apply suitable anti-seize compound. Inspect caliper and seals for damage. Position bleed bottle, connect bleed hose to bleed screw and loosen screw. (Scheme 8)
2. Press piston into caliper housing then tighten bleed screw to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Disconnect bleed hose and remove bottle. Install brake pads to caliper housing. Clean and inspect guide pins, replace if corroded or damaged. DO NOT lubricate. Position and align caliper housing to carrier, fit guide pins and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
3. Install caps to guide pin dust covers. Install anti-rattle spring to caliper housing. Repeat procedure for other side. Install sensor to pad. Depress brake pedal several times to seat pads. Check and top-up fluid level. Install front wheels and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 8

Removal & Installation

To remove and install front brake caliper, see FRONT BRAKE DISC .

1. Raise and support vehicle. Remove front wheels. Remove 2 bolts securing brake caliper to hub. (Scheme 9) Release caliper from hub and tie aside. DO NOT allow caliper to hang on brake hose. Remove disc set screw and remove disc. (Scheme 10) Using a wire brush, remove corrosion from mating faces. Clean with a suitable solvent.
2. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 9

Scheme 10

1. Raise and support vehicle. Remove rear wheels. On right side, remove rear pad wear sensor. Remove anti-rattle spring from caliper housing. (Scheme 11) Remove 2 caps from guide pin dust covers. Remove 2 guide pins from caliper housing.
2. Release caliper housing from caliper carrier and tie aside. Remove brake pads from caliper housing, mark their fitted position if they are to be refitted. Repeat procedure for other side.

Scheme 11

1. To install, clean caliper housing and caliper carrier using brake cleaning fluid. Clean brake pad, caliper housing and carrier contact areas and apply suitable anti-seize compound. Inspect caliper and seals for damage. Position bleed bottle, connect bleed hose to bleed screw and loosen screw. (Scheme 12)
2. Press piston into caliper housing then tighten bleed screw to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Disconnect bleed hose and remove bottle. Install brake pads to caliper housing. Clean and inspect guide pins, replace if corroded or damaged. DO NOT lubricate. Position and align caliper housing to carrier, fit guide pins and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
3. Install caps to guide pin dust covers. Install anti-rattle spring to caliper housing. Repeat procedure for other side. Install sensor to pad. Depress brake pedal several times to seat pads. Check and top-up fluid level. Install wheel(s) and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 12

To remove and install rear brake caliper, see REAR BRAKE DISC .

1. Raise and support vehicle. Remove rear wheel. Remove 2 bolts securing brake caliper to hub. (Scheme 13) Release caliper from hub and tie aside. DO NOT allow caliper to hang on brake hose. Remove disc set screw and remove disc. (Scheme 14) Using a wire brush, remove corrosion from mating faces. Clean with a suitable solvent.
2. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Adjust parking brake. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) under ADJUSTMENTS.

Scheme 13

Scheme 14

"A" PILLAR UPPER TRIM FINISHER

1. Disconnect negative battery cable. See «DISCONNECTING & RECONNECTING BATTERY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Disable air bags. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/range-rover/iii-2002-2005/remont/airbag/#air-bag-restraint-systems) article. Release door aperture seal. Remove cover from screw. (Scheme 15) Remove Torx screw securing "A" pillar trim. Release 3 clips securing "A" pillar trim and remove trim.
2. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 15

1. Using a trim removal tool, release 7 clips securing front tread-plate carpet retainer to sill. (Scheme 16) Remove tread-plate carpet retainer. DO NOT carry out further dismantling if component is removed for access only. Release sufficient door aperture seal to access lower trim finisher. (Scheme 17) Release and remove finisher horizontally from 2 retaining clips. DO NOT carry out further dismantling if component is removed for access only.
2. To install, reverse removal procedure.

Scheme 16

Scheme 17

1. Position container to collect fluid. Disconnect low fluid level sensor connector. (Scheme 18) Release harness from clip. Release clip and disconnect precharge pump feed hose. Plug hose immediately to prevent fluid loss from precharge pump. Release 2 clips and remove reservoir. (Scheme 19) Remove and discard 2 reservoir seals. Plug openings.
2. To install, clean reservoir and master cylinder mating faces. Install seals. Install reservoir. Connect precharge pump feed hose and secure with clip. Secure harness to clip. Connect connector to low fluid level sensor. Bleed brakes using TestBook/T4 scan tool.

Scheme 18

Scheme 19

1. Individually release 4 internal clips securing air vent to finisher, apply an even outward pressure until the last clip is released. (Scheme 20) Disconnect connectors and release harness from vent. (Scheme 21) Release air distribution cable from ratchet assembly and remove vent. DO NOT carry out further dismantling if component is removed for access only.
2. To install, reverse removal procedure.

Scheme 20

Scheme 21

1. Remove center console finisher. See «CENTER CONSOLE FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove both center console closing panels. See «CENTER CONSOLE CLOSING PANELS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove 2 Torx screws securing large cubby box liner, remove liner. (Scheme 22) Remove 2 Torx screws securing ignition switch to center console. (Scheme 23) Remove 4 Torx screws securing center console to fascia.
3. Remove 2 Torx screws and collect washers from base of large cubby box. (Scheme 24) Remove 2 screws securing center console rear closing panel. (Scheme 25) Release clips and remove panel. Raise rear of center console, disconnect 3-pin connector from center console and collect air duct adaptor. Disconnect 3 Lucar connectors from accessory power socket.
4. To install, position center console and connect connectors to rear of console. Install air duct adaptor and align center console to mountings. Secure center console with screws. Install rear closing panel and secure with clips and screws. Position ignition switch and secure with screws. Install cubby box and secure with Torx screws. Install both center console closing panels. Install center console finisher.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Remove screw securing closing panel to fascia. (Scheme 26) Release 2 clips securing closing panel and remove from lower fascia. DO NOT carry out further dismantling if component is removed for access only.
2. To install, reverse removal procedure.

Scheme 26

1. Remove gear selector cover. See «GEAR SELECTOR COVER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove gaiter from parking brake lever grip. (Scheme 27) Release and remove parking brake lever grip. Open cubby box lids, carefully release clips and remove finisher.
2. Remove 6 Torx screws securing finisher to center console, fully apply parking brake. (Scheme 28) Release finisher from clips, raise and disconnect 3 Lucar connectors from accessory power socket. Disconnect connector from closing panel lamp assembly. Remove center console finisher. DO NOT carry out further dismantling if component is removed for access only.
3. To install, position center console finisher and connect Lucars connectors. Connect connector to closing panel lamp assembly. Install finisher and secure with Torx screws. Install parking brake lever grip and secure gaiter. Install and secure small cubby box finisher. Close cubby box lids. Install gear selector cover.

Scheme 27

Scheme 28

1. Remove fascia end closing panel. See «FASCIA END CLOSING PANEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove passenger side closing panel. See «PASSENGER SIDE FOOTWELL CLOSING PANEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove drivers side "A" pillar lower trim finish. See «"A" PILLAR LOWER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove cover from lower finisher for access to Torx screw. (Scheme 29) Remove 3 Torx screws securing upper finisher to fascia. Disconnect on board diagnostics port connector. Remove finisher. Remove clips from finisher.
3. To install, reverse removal procedure.

Scheme 29

1. Remove fascia end closing panel. See «FASCIA END CLOSING PANEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Individually release 4 internal clips securing face level air vent to finisher, apply an even outward pressure until the last clip is released. (Scheme 30) Remove face level air vent from finisher. Disconnect face level air vent connector and remove vent from vehicle. Remove "A" pillar upper trim finisher. See «"A" PILLAR UPPER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__a-pillar-upper-trim-finisher).
2. Remove 3 Torx screws securing upper finisher to fascia. (Scheme 31) Release upper finisher from fascia and disconnect switch connector. Disconnect footwell lamp connector. Remove upper finisher. DO NOT carry out further dismantling if component is removed for access only.
3. To install, reverse removal procedure.

Scheme 30

Scheme 31

1. Raise and support vehicle. Disconnect negative battery cable. See «DISCONNECTING & RECONNECTING BATTERY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Release precatalyst HO2S harness from clips, remove connector from retaining clips and disconnect. (Scheme 32) Release post catalyst HO2S harnesses from clips, remove connectors from clips and disconnect. (Scheme 33) Remove and discard 4 nuts securing front pipe flanges to exhaust manifolds, release front pipe from flanges and move aside. (Scheme 34)
2. Remove and discard the 4 nuts securing intermediate silencer mountings to body. (Scheme 35) Remove 8 nuts securing rear silencer rubber mountings to body and with assistance remove exhaust assembly from vehicle. (Scheme 36) DO NOT carry out further dismantling if component is removed for access only.
3. To install, with assistance fit exhaust system to vehicle, align flanges to manifolds, fit and lightly tighten bolts. Install one pair of rear silencer brackets to body and lightly tighten bolts. Align remaining mounting brackets to body, fit nuts and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
4. Check exhaust for correct alignment. Align exhaust flange and tighten NEW nuts evenly to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Connect negative battery cable. Start and run engine to check for leaks.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Release sufficient door aperture seal to access closing panel. (Scheme 37) Release 3 clips securing end closing panel to fascia and carefully remove panel. DO NOT carry out further dismantling if component is removed for access only.
2. To install, reverse removal procedure.

Scheme 37

FRONT WHEEL HUB ASSEMBLY

1. Raise and support vehicle. Remove wheels. Release axle shaft hub nut stake. With an assistant applying brakes, remove and discard drive shaft hub nut. (Scheme 38) Remove brake discs. See «FRONT BRAKE DISC»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Release ABS sensor lead from clip. (Scheme 39) Release sensor lead from damper, remove Allen screw and release ABS sensor from hub. Remove nut securing height sensor link to lower control arm and release link. (Scheme 40) Use an open ended spanner on flats provided to prevent ball joint rotating.
2. Loosen bolt securing lower control arm to subframe one quarter of a turn. Remove nut securing lower control arm ball joint to hub. Using Ball Joint Splitter (LRT-54-027), release lower control arm ball joint and disconnect lower control arm from hub. (Scheme 41)
3. Loosen bolt securing front stabilizer rod to subframe one quarter of a turn. (Scheme 42) Remove nut securing front stabilizer rod to ball joint. Using Ball Joint Splitter (LRT-54-027), release stabilizer rod from ball joint. (Scheme 43) Remove and discard nut securing tie rod ball joint to steering arm. (Scheme 44) Install an M14 nut to ball joint pin, flush with end of pin. Using Ball Joint Splitter (LRT-57-036), separate ball joint pin from steering arm. Remove M14 nut and release ball joint pin from steering arm.
4. Install Axle Shaft Installer/Remover, Remover Screw (LRT-60-030/3) to Axle Shaft Installer/Remover (LRT-60-030/1) and fit to hub with Axle Shaft Installer/Remover Spacer (LRT-60-030/2). (Scheme 45) Secure with Axle Shaft Installer/Remover Nuts (LRT-60-030/5). Tighten center screw to press drive shaft from flange. Remove tools.
5. Remove 2 nuts and bolts securing hub to damper. (Scheme 46) Remove hub assembly.

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Clean hub to damper mating faces. Clean drive shaft and flange splines. Lightly lubricate splines. Position hub assembly and fit upper bolt, locate drive shaft to hub, align hub and fit lower bolt. Tighten bolts securing hub to damper to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
2. Install Axle Shaft Installer/Remover Install Screw (LRT-60-030/4) to drive shaft. (Scheme 47) Install Axle Shaft Installer/Remover (LRT-60-030/1) with Axle Shaft Installer/Remover Spacer (LRT-60-030/2) and secure with Axle Shaft Installer/Remover Nuts (LRT-60-030/5). Install nut to Axle Shaft Installer/Remover, Installer Screw (LRT-60-030/4) and tighten nut to pull drive shaft into drive flange.
3. Remove tools. Clean ball joint tapers and taper seats. Connect ball joint to steering arm, fit NEW nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Connect stabilizer rod to ball joint, fit nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Connect lower control arm ball joint to hub, fit nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
4. Replace bolts securing lower control arm to subframe and stabilizer rod to subframe but DO NOT tighten at this stage. Connect height sensor link to lower control arm, fit nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Ensure height sensor arm is pointing outwards. Clean ABS sensor, smear sensor with an anti-seize grease and fit sensor to hub. Install Allen screw securing ABS sensor and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Secure sensor lead to damper. Install front brake disc.
5. Install NEW hub nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Stake nut to shaft. Install wheels and tighten nuts to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Tighten bolt securing lower control arm to subframe to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Tighten bolt securing stabilizer rod to subframe to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Check front wheel alignment. See «SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

Scheme 47

1. Remove hub assembly. See «FRONT WHEEL HUB ASSEMBLY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__front-wheel-hub-assembly). Remove 3 bolts securing brake disc shield. (Scheme 48) Position Bearing Press Pins (LRT-60-033/3) to brake caliper mounting bolt locations and secure with bolts. (Scheme 49) Install Bearing Press Adapter (LRT-60-033/5) to drive flange. Locate Bearing Press Plate (LRT-60-033/2) to pins, fit Bearing Press Pin (LRT-60-033/4) over steering arm and secure to plate. (Scheme 50) Ensure pins located in holes are marked FRONT.
2. Screw Bearing Press Ram (LRT-60-033/1) into plate and press drive flange from hub. (Scheme 51) Outer bearing track will remain on drive flange. Remove Bearing Press Plate (LRT-60-033/2) and Bearing Press Pin (LRT-60-033/4).
3. Remove and discard circlip. (Scheme 52) Install Bearing Press Adapter (LRT-60-033/6) to bearing and, using method previously described, remove bearing. Remove Bearing Press Pins (LRT-60-033/3). Remove bearing track from drive flange using a bearing separator. (Scheme 53)

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Clean hub and drive flange. Position Bearing Press Anvil (LRT-60-033/10) to bed of bearing press and locate hub on anvil. (Scheme 54) Ensure hub and bearing mating surfaces are clean and dry. Apply Stud/Bearing Lubricant (STC 50553) to bearing mating surface in hub for half its length. Press bearing into hub using Bearing Press Adapter (LRT-60-033/12).
2. Install NEW circlip. Install Bearing Press Support (LRT-60-033/11) to bearing press anvil, and press flange into bearing using Bearing Press Adapter (LRT-60-033/12). (Scheme 55) Remove tools. Clean disc shield and mating face, align shield and fit and tighten bolts. Install hub assembly.

Scheme 54

Scheme 55

1. Turn ignition on, depress brake pedal and move gear lever to Drive. Turn ignition off. Release clips and gear selector cover from center console. (Scheme 56) Carefully disconnect 4 connectors from gear selector panel. Remove gear lever knob and cover by pulling sharply upward. Release clips securing gear lever gaiter to center console cover, remove knob and gaiter.
2. To install, position cover and connect connectors, secure cover to center console. Install gear lever knob to gear lever. Install gaiter to center console and secure with clips. Turn ignition on, return gear lever to Park, turn ignition off.

Scheme 56

1. Raise and support vehicle. Remove left front wheel. Open cover on connector housing, release and disconnect pad wear sensor connector. (Scheme 57) Release sensor lead from body bracket, clip, brake hose bracket and bleed screw dust cap. (Scheme 58) Disconnect pad wear sensor from brake pad. Remove sensor.
2. To install, install reverse removal procedure. Install wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 57

Scheme 58

1. Remove drivers side upper trim finisher. See «DRIVERS SIDE UPPER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove passengers side lower trim finisher. See «PASSENGERS SIDE LOWER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove 2 Torx screws securing glove box from underside of fascia. (Scheme 59) Open glove box. Remove 5 Torx screws securing glove box. Disconnect connector from lamp. (Scheme 60) Release cable from glove box latch.
3. If vehicle is equipped with CD changer, remove 2 Torx screws securing CD changer to glove box. (Scheme 61) Withdraw CD changer from glove box and disconnect link lead and both connectors. (Scheme 62) Remove the CD changer. Remove glove box assembly. DO NOT carry out further dismantling if component is removed for access only.
4. To install, reverse removal procedure.

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Remove rotary coupler. See «ROTARY COUPLER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__rotary-coupler). Remove glove box. See «GLOVE BOX»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove center air vent. See «CENTER AIR VENT»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove drivers side upper trim finisher. See «DRIVERS SIDE UPPER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove drivers side lower trim finisher. See «DRIVERS SIDE LOWER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove 6 Torx screws securing lower fascia shroud. Carefully release 7 clips securing shroud to carrier assembly. Remove shroud. (Scheme 63)
3. To install, reverse removal procedure.

Scheme 63

1. Remove brake fluid reservoir. See «BRAKE FLUID RESERVOIR & SEALS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove and plug brake lines. Remove and discard 2 nuts securing master cylinder to servo, and remove master cylinder. Remove and discard "O" ring. (Scheme 64)
2. To install, clean master cylinder and servo mating surfaces. Install NEW "O" ring. Align push rod and position master cylinder to servo. Install NEW nuts securing brake master cylinder and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Clean brake pipe unions. Connect brake pipes to master cylinder and tighten unions to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Install fluid reservoir.

Scheme 64

1. Raise and support vehicle. Remove rear brake discs. See «REAR BRAKE DISC»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove brake shoe upper return spring. (Scheme 66) Rotate brake shoe retainers 90 degrees and remove. Remove lower return spring and adjuster from brake shoes. (Scheme 67) Remove shoe expander. (Scheme 68)
2. Remove rear drive shaft. See «REAR DRIVE SHAFT»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__rear-drive-shaft). Remove center console. See «CENTER CONSOLE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove cable clip and disconnect parking brake lever cable from compensator. (Scheme 70) Withdraw parking brake cable from body.
3. Remove bolt securing parking brake cable to backplate. (Scheme 65) Release cable from chassis clip. Remove bolt securing cable retaining clip to subframe. Remove cable mounting bracket from parking brake cable.

Scheme 65

1. Install support bracket to cable. Clean expander. Position parking brake cable and secure to expander. Install and secure parking brake cable to backplate, tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) .
2. Position cable support clip to subframe, tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Secure cable in chassis clip. Feed cable through body to parking brake lever. Connect cable to compensator. Secure cable retaining clip to parking brake assembly. Install center console. Install rear drive shaft.
3. Clean backplate and brake disc with brake cleaning fluid. Clean brake adjuster, lubricate threads with grease and set to minimum extension. Assemble brake shoes with adjuster and lower return spring. Position brake shoe assembly. Install retainers and upper return spring. Install rear brake disc. Check parking brake operation, adjust if necessary. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) under ADJUSTMENTS.

1. Raise and support vehicle. Remove wheels. Remove brake disc. See «REAR BRAKE DISC»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove brake shoe upper return spring. (Scheme 66) Rotate brake shoe retainers 90 degrees and remove.
2. Remove brake shoe assembly complete with lower spring and adjuster. Remove lower return spring and adjuster from brake shoes. (Scheme 67) Remove shoe expander. (Scheme 68) Repeat procedure for other side.

Scheme 66

Scheme 67

Scheme 68

1. Clean backplate and brake disc with brake cleaning fluid. Clean expander. Clean brake adjuster, lubricate threads with grease and set to minimum extension. Install expander. Assemble brake shoes with adjuster and lower return spring. Position brake shoe assembly, fit retainers and upper return spring. Install brake disc.
2. Repeat procedure for other side. Install rear wheels and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Adjust parking brake. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) under ADJUSTMENTS.

1. Remove center console. See «CENTER CONSOLE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Release and remove air duct. (Scheme 69) Release clip and disconnect parking brake cables from compensator. (Scheme 70) Release connector from switch. (Scheme 71) Remove 2 nuts securing parking brake lever. (Scheme 72) Remove parking brake lever.
2. To install, install parking brake lever to bracket, fit nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Connect lead to switch. Connect cables to compensator. Install air duct. Install center console. Check parking brake operation, adjust if necessary. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) under ADJUSTMENTS.

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Remove closing panel from passenger side of the center console. See «CENTER CONSOLE CLOSING PANELS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove 4 screws securing closing panel. (Scheme 73) Disconnect connector from closing panel lamp assembly. Remove passenger side footwell closing panel. Release lamp assembly from closing panel.
2. To install, reverse removal procedure.

Scheme 73

1. Remove center console. See «CENTER CONSOLE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove screw, disconnect connector and remove switch. (Scheme 74)
2. To install, reverse removal procedure. Ensure lug on parking brake lever locates in hole in switch.

Scheme 74

1. Remove fascia end closing panel. See «FASCIA END CLOSING PANEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove passenger side "A" pillar lower trim finisher. See «"A" PILLAR LOWER TRIM FINISHER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove passenger side footwell closing panel. See «PASSENGER SIDE FOOTWELL CLOSING PANEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. If equipped, remove venture cam. Remove cover from lower finisher for access to Torx screw. (Scheme 29) Remove 3 Torx screws securing upper finisher to fascia. Remove finisher. Remove clips from finisher.
3. To install, reverse removal procedure.

1. Remove engine compartment bulkhead closing panel. Remove brake master cylinder. See «MASTER CYLINDER»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Disconnect vacuum pipe from vacuum booster. (Scheme 75) Remove nut securing alarm sounder to mounting bracket and move aside. (Scheme 76) Remove bolt securing precharge pump bracket to body. Release pump from rubber mounting. Disconnect connector. Remove pump.
2. Remove lower fascia shroud. See «LOWER FASCIA SHROUD»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove clip and clevis pin securing vacuum booster push rod to brake pedal. (Scheme 77) Remove and discard 2 nuts securing brake vacuum booster. Remove brake vacuum booster.

Scheme 75

Scheme 76

Scheme 77

Note. Nuts securing brake vacuum booster to pedal bracket must be retorqued after 20 minutes have elapsed.

1. Install NEW gasket to brake vacuum booster and install vacuum booster. On right hand drive models, when fitting the vacuum booster, ensure air suspension pipe is not trapped behind it. Install NEW nuts securing brake vacuum booster to pedal bracket and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Clean clevis pin and smear with grease. Align push rod, fit clevis pin and secure with clip. Install shroud. Locate precharge pump to mounting rubbers.
2. Connect connector. Install bolt securing precharge pump and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Position alarm sounder to bracket, fit nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Connect vacuum pipe. Install brake master cylinder. Install bulkhead closing panel.

1. Raise and support vehicle. Remove right rear wheel. Remove 5 screws securing wheel arch liner and release liner for access to connector housing. (Scheme 78)
2. Open cover on connector housing, release and disconnect pad wear sensor connector then release sensor lead from spring turret, suspension arm and bleed screw dust cap. (Scheme 79) Disconnect pad wear sensor from brake pad. Remove sensor.
3. To install, reverse removal procedure. Install wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 78

Scheme 79

REAR DRIVE SHAFT

1. Raise and support vehicle. Disconnect negative battery cable. See «DISCONNECTING & RECONNECTING BATTERY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove 5 nuts securing left heat shield. Remove heat shield. (Scheme 80) Remove 8 nuts securing center heat shield and remove shield. (Scheme 81)
2. Remove 8 hexagonal headed screws securing fuel tank heat shield and remove shield. (Scheme 82) Raise vehicle to allow drive shaft to rotate. Reference mark rear drive shaft for reassembly. (Scheme 83) Remove 6 nuts securing drive shaft to differential flange. Release joint from differential flange and support the drive shaft.
3. Remove 6 Torx bolts securing drive shaft to transfer gearbox flange. (Scheme 84) Release joint from transfer gearbox flange and support the drive shaft. Remove 2 nuts securing support bearing and remove drive shaft. (Scheme 85)

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Install drive shaft. Install nuts securing support bearing but DO NOT tighten at this stage. Clean drive shaft joints and mating faces. Install drive shaft joints to flanges and align marks. Tighten Torx bolts securing drive shaft to transfer gearbox flange to specification and tighten nuts securing drive shaft to differential flange to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) .
2. Tighten nuts securing support bearing to body to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications) . Ensure support bearing is not under any tension before tightening bolts. Install fuel tank heat shield and secure with screws. Install center heat shield and secure with nuts. Install left heat shield and secure with nuts. Install exhaust system.

1. Raise and support vehicle. Remove wheels. Restrain ball joint pin and remove nut securing stabilizer rod to hub. (Scheme 86) Remove nut and bolt securing sensor link to lower control arm. (Scheme 87) Reference mark eccentric in relationship to subframe. (Scheme 88) Remove bolt securing stabilizer rod to subframe. Discard bolt. Collect special washer. Remove stabilizer rod.
2. Clean ball joint pin and mating face in hub. Install stabilizer rod, NEW bolt, special washer and nut. Align reference marks and lightly tighten bolt. Install nut to stabilizer rod ball joint and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Align height sensor link to lower control arm, fit nut and bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Ensure height sensor arm is pointing outwards.
3. Install wheels and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Check wheel alignment. See «SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT. Tighten bolt securing stabilizer rod subframe to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 86

Scheme 87

Scheme 88

1. Raise and support vehicle. Remove wheels. Release axle shaft hub nut stake. With an assistant applying brakes, remove and discard axle shaft hub nut. (Scheme 89) Remove brake disc. See «REAR BRAKE DISC»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove brake shoe upper return spring. (Scheme 90) Rotate brake shoe retainers 90 degrees and remove. Remove brake shoe assembly complete with lower spring and adjuster. (Scheme 91) Remove shoe expander. (Scheme 92) Remove rear stabilizer rod. See «REAR STABILIZER ROD»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Release ABS sensor lead from hub. (Scheme 93) Remove bolt securing ABS sensor, release sensor and position aside.
3. Remove Allen screw securing hand brake cable bracket. (Scheme 94) Remove bolt securing parking brake cable to backplate. Release parking brake cable from backplate. Install Axle Shaft Installer/Remover, Remover Screw (LRT-60-030/3) to (LRT-60-030/1) and fit to hub with Axle Shaft Installer/Remover Spacer (LRT-60-030/2). (Scheme 95) Secure with Axle Shaft Installer/Remover Nuts (LRT-60-030/5). Tighten center screw to press drive shaft from flange. Remove tools.
4. Reference mark eccentric in relationship to upper control arm. (Scheme 96) Remove and discard nut and bolt securing hub to upper control arm. Release hub from arm. Remove and discard nut and bolt securing lower control arm to hub. (Scheme 97) Remove hub assembly.

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

1. Clean drive shaft and flange splines. Lightly lubricate splines. Clean hub and mating faces on upper and lower control arms. Position hub assembly, fit NEW lower bolt and locate axle shaft in hub. Align hub to upper control arm, fit NEW bolt, align eccentric to reference mark and lightly tighten. Tighten bolt securing lower control arm to hub to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
2. Install Axle Shaft Installer/Remover, Installer Screw (LRT-60-030/4) to axle shaft. (Scheme 98) Install Axle Shaft Installer/Remover (LRT-60-030/1) with Axle Shaft Installer/Remover Spacer (LRT-60-030/2) and secure with Axle Shaft Installer/Remover Nuts (LRT-60-030/5). Install nut to Axle Shaft Installer/Remover, Installer Screw (LRT-60-030/4) and tighten nut to pull drive shaft into drive flange. Remove tools. Locate parking brake cable to backplate, fit bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Position parking brake cable bracket to upper control arm, fit Allen screw and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).
3. Clean ABS sensor, smear sensor with an anti-seize grease and fit sensor to hub. Install Allen screw securing ABS sensor and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Install stabilizer rod. Clean backplate and brake disc with brake cleaning fluid.
4. Clean expander. Install expander. Position brake shoe assembly, fit retainers and upper return spring. Install brake disc. Install NEW hub nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Stake nut to shaft. Adjust parking brake. See «PARKING BRAKE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__parking-brake) under ADJUSTMENTS.
5. Install wheels and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). Lower vehicle. Check wheel alignment. See «SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT. Tighten bolt securing upper control arm to hub to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications).

Scheme 98

1. Remove hub assembly. See «REAR WHEEL HUB ASSEMBLY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Remove 4 bolts securing backplate to hub. (Scheme 99) Install Bearing Press Adapter (LRT-60-033/5) to drive flange. (Scheme 100)
2. Position Bearing Press Plate (LRT-60-033/2). (Scheme 101) Install Bearing Press Pin (LRT-60-033/9) to tie rod bar location and secure to plate. Locate Bearing Press Pins (LRT-60-033/7) and (LRT-60-033/8) to plate and align to brake caliper mounting bolt locations. Install bolts to secure pins. Pins located in holes should be marked REAR, with longer Bearing Press Pin (LRT-60-033/7) aligned with caliper top mounting bolt hole.
3. Screw Bearing Press Ram (LRT-60-033/1) into plate and press drive flange from hub. (Scheme 102) Outer bearing track will remain on drive flange. Remove brake disc shield. Remove Bearing Press Plate (LRT-60-033/2) and Bearing Press Pin (LRT-60-033/9). Remove Bearing Press Pins, (LRT-60-033/7) and (LRT-60-033/8).
4. Remove and discard circlip. (Scheme 103) Position hub to bed of bearing press, fit Bearing Press Adapter (LRT-60-033/6) to bearing and press out bearing. Remove bearing track from drive flange using a bearing separator. (Scheme 104)

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

1. Clean hub and drive flange. Position Bearing Press Anvil (LRT-60-033/10) to bed of Bearing Press and locate hub on Bearing Press Anvil. (Scheme 105) Ensure hub and bearing mating surfaces are clean and dry. Apply Stud/Bearing Lubricant (STC 50553) to bearing mating surface in hub for half its length. Press bearing into hub using Bearing Press Adapter (LRT-60-033/12).
2. Install NEW circlip. (Scheme 106) Clean backplate and mating face, fit backplate and fit and tighten bolts. Install Bearing Press Bearing Support (LRT-60-033/11) to Bearing Press Anvil, and press flange into bearing using Bearing Press Adapter (LRT-60-033/12). Remove tools. Install hub assembly.

Scheme 105

Scheme 106

ROTARY COUPLER

1. Disconnect negative battery cable. See «DISCONNECTING & RECONNECTING BATTERY»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc). Disable air bags. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/range-rover/iii-2002-2005/remont/airbag/#air-bag-restraint-systems) article. Remove steering wheel. See «STEERING WHEEL»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__steering-wheel). Remove steering column cover. See «STEERING COLUMN NACELLE»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc).
2. Remove 4 Torx screws securing rotary coupler assembly to column. (Scheme 107) Release coupler assembly. Disconnect 5 connectors from rotary coupler. (Scheme 108) Remove rotary coupler assembly. DO NOT carry out further dismantling if component is removed for access only.
3. To install, reverse removal procedure.

Scheme 107

Scheme 108

1. Fully extend the steering column for access. Remove 3 Torx screws securing steering column cover. (Scheme 109) Release cover from clips securing assembly to column extension gaiter. Remove steering column cover.
2. To install, push steering column extension gaiter fully forwards and fit lower half of cover. Install and tighten the 2 (T25) Torx screws. Ensure the lower half of cover does not foul the steering wheel. Install upper half of cover and ensure that clips engage with lower half. Secure upper half of cover with T20 Torx screw. Install and secure steering column extension gaiter to cover. Ensure the cover does not foul the steering wheel.

Scheme 109

STEERING WHEEL

Note. Centralize the steering wheel with the wheels in the straight ahead position. This will ensure that the rotary coupler is locked as the steering wheel is removed.

1. Remove AIRBAG module from steering wheel. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/range-rover/iii-2002-2005/remont/airbag/#air-bag-restraint-systems) article. On models quipped with heated steering wheel, disconnect connector from rotary coupler. Restrain steering wheel and remove retaining bolt. (Scheme 110)
2. With the wheels in the straight ahead position, the bottom timing mark on the steering column must be aligned with the steering wheel mark. (Scheme 111) The steering column timing marks are 105 degrees apart. Note steering wheel to column alignment marks and remove steering wheel. DO NOT carry out further dismantling if component is removed for access only.
3. To install, ensure wheels are straight ahead and rotary coupler is locked in correct position. Carefully fit steering wheel, engage coupler and align to column. Install steering wheel retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/mechanical-hydraulic/#disc__torque-specifications). On models equipped with heated steering wheel, connect connector to rotary coupler. Install air bag. See «AIR BAG RESTRAINT SYSTEMS»(/land-rover/range-rover/iii-2002-2005/remont/airbag/#air-bag-restraint-systems) article.

Scheme 110

Scheme 111

OVERHAUL

Note. For exploded view of front brake caliper (Scheme 112) For exploded view of rear brake caliper (Scheme 113)

Scheme 112

Scheme 113

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

1. For disc brake specifications on 2003 vehicles, see «DISC BRAKES»(ref-160646-S27092559012004021800000) in SPECIFICATIONS article.
2. For disc brake specifications on 2004 vehicles, see «DISC BRAKES»(ref-162011-S21236460052004051200000) in SPECIFICATIONS article.

PARKING BRAKE SPECIFICATIONS

PARKING BRAKE SPECIFICATIONS

See also:
• AIR BAG RESTRAINT SYSTEMS
• SPECIFICATIONS
• TORQUE SPECIFICATIONS
• PARKING BRAKE
• BLEEDING BRAKE SYSTEM
• FRONT BRAKE DISC
• "A" PILLAR UPPER TRIM FINISHER
• FRONT WHEEL HUB ASSEMBLY
• ROTARY COUPLER
• REAR DRIVE SHAFT
• STEERING WHEEL