3 Undo the retaining bolt and release the
flexible brake hose support clip from the
suspension strut (see illustration).
4 Withdraw the carrier bracket, complete with
caliper and brake pads, from the disc and hub
carrier. Tie the caliper assembly from a
convenient place under the wheelarch to
avoid straining the brake hose (see
illustration).
5 The inspection procedures are the same as
for the front brake disc, and reference should
be made to Section 6, paragraphs 4 to 7
inclusive.
Removal
6 Remove the brake caliper and carrier
bracket as described in paragraphs 1 to 4.
7 Undo the two retaining screws and
withdraw the disc from the hub flange (see
illustrations). If it is tight, tap it lightly from
behind using a hide or plastic mallet.
Refitting
8 Refitting is a reversal of removal. Ensure
that the mating face of the disc and hub
flange are thoroughly clean, and tighten all
retaining bolts to the specified torque.
11 Master cylinder -
removal and refitting
3
Note: Before starting work, refer to the
warning at the beginning of Section 2
concerning the dangers of hydraulic fluid.
Removal
1 Disconnect the wiring multiplug from the
fluid level warning indicator in the reservoir
filler cap, then remove the filler cap from the
reservoir. Note that the filler cap must not be
inverted. The reservoir should now be
emptied by syphoning or drawing out the fluid
with a pipette.
2 Place rags beneath the master cylinder to
absorb any remaining brake fluid when the
pipe unions are undone. If any brake fluid is
spilled on the car paintwork, wash it off
immediately with copious amounts of cold
water.
3 On manual transmission models, detach
the clutch fluid supply hose from the side of
the reservoir.
4 Unscrew the two brake pipe union nuts,
and carefully withdraw the pipes from the
master cylinder (see illustration). Tape over
the pipe ends to prevent dirt ingress.
5 Undo the two nuts, remove the washers,
and withdraw the master cylinder from the
servo unit. Recover the O-ring seal between
master cylinder and servo.
Refitting
6 Refitting is a reversal of removal. Renew the
master cylinder-to-servo O-ring seal, and
tighten all retaining nuts to the specified
torque. Bleed the brakes as described in
Section 2. On manual transmission models,
bleed the clutch hydraulic system as
described in Chapter 6.
12 Master cylinder (non-ABS
models) - overhaul
4
Note: Two different types of master cylinder
have been fitted to non-ABS equipped Rover
models covered by this manual (see
illustrations). The following procedures are
mainly applicable to the early unit fitted until
approximately October 1991. The later unit is
similar, but at the time of writing no specific
overhaul information was available from the
manufacturer.
1 Remove the master cylinder from the car as
described in the previous Section. Drain any
fluid remaining in the reservoir, and prepare a
clean, uncluttered working surface ready for
dismantling.
2 Hold the cylinder body firmly, and push the
reservoir sideways to release it from its seals.
Lift the reservoir off, and remove the two seals
from the fluid inlet ports.
3 Push the primary piston down the cylinder
bore slightly, and hold it there. Locate the
stop-pin in the secondary inlet port, and
withdraw the pin using pointed-nose pliers.
4 With the piston held down, extract the
circlip, using circlip pliers, from the cylinder
bore end, and remove the washer behind the
circlip.
5 Using a small blunt screwdriver, hook out
the O-ring seal from the groove in the cylinder
bore.
6 Remove the primary piston.
7 Lubricate the cylinder bore with clean
hydraulic fluid to aid removal of the secondary
piston.
8 Tap the cylinder body on a block of wood
to release the secondary piston, then
withdraw the piston from the cylinder bore.
9 Remove the secondary piston spring, seal
retainer, rear seal, washer and front seal.
10 Remove the seal housing, seal and
washer from the primary piston. Do not
dismantle the primary piston further, as seals
Braking system 9•9
10.7a Undo the two retaining screws . . .10.4 Tie up the caliper assembly to avoid
straining the brake hose
10.3 Release the rear flexible brake hose
support clip from the suspension strut
11.4 Unscrew the two brake pipe unions
(arrowed) at the master cylinder
10.7b . . . and withdraw the rear disc from
the hub flange
9
1380 Rover 800 Series Remake
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