9
Chapter 9
Braking system
System type
Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockheed single or dual circuit hydraulic, servo assisted on certain
models
Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical by cables to rear brakes
Front drum brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin leading shoe
Drum diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.0 mm
Minimum brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
Front disc brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc with twin piston caliper
Disc diameter:
Cooper S models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190.5 mm
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.4 mm
Maximum disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Minimum brake pad thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
Rear brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single leading shoe drum
Drum diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.0 mm
Minimum brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 mm
Torque wrench settings Nm lbf ft
Driveshaft retaining nut (disc brake models):
With multiple split pin holes in driveshaft . . . . . . . . . . . . . . . . . . . . . . 207 150
With single split pin hole in driveshaft . . . . . . . . . . . . . . . . . . . . . . . . 255 to 270 188 to 200
Brake caliper retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 38
Disc to hub flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 42
Master cylinder body outlet plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 28
Master cylinder pressure differential piston end plug . . . . . . . . . . . . . . 45 33
Pressure differential warning actuator end plug . . . . . . . . . . . . . . . . . . . 35 26
Pressure differential warning actuator failure switch . . . . . . . . . . . . . . . 19 14
Brake disc - inspection, removal and refitting . . . . . . . . . . . . . . . . . . 9
Brake drum - removal, inspection and refitting . . . . . . . . . . . . . . . . . 4
Brake fluid level check . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pad wear check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake shoe wear check . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Disc brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 8
Disc brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drum brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Drum brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drum brake wheel cylinder - removal, overhaul and refitting . . . . . . 6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Handbrake cable - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 10
Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic pipes and hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder (single circuit system) - removal, overhaul and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure differential warning actuator (dual circuit system) - removal,
overhaul and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure reducing valve (dual circuit system) - removal and refitting . 19
Pressure regulating valve (single circuit system) - removal, overhaul
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tandem master cylinder (dual circuit system) - identification and
modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tandem master cylinder (type 1) - removal, overhaul and refitting . . 14
Tandem master cylinder (type 2) - removal, overhaul and refitting . . 15
Tandem master cylinder (type 3) - removal, overhaul and refitting . . 16
Tandem master cylinder (type 4) - removal, overhaul and refitting . . 17
Underbody and fuel/brake line check . . . . . . . . . . . . . . .See Chapter 1
Vacuum servo unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . 21
Vacuum servo unit air filter (1989 models onward) - renewal . . . . . . 22
9•1
Specifications
Contents
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
5
4
3
2
1
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