Land Rover Discovery 3 Bodsy S Brake Bible Bodsworth Manual

							 
  Land Rover 
Discovery 3 
 
Ian Bodsworth 
WWW.DISCO3CLUB.CO.UK in co-
operation with contributions from 
DISCO3.CO.UK 
June 2011 
Version 1.6 
© Copyright Ian Bodsworth 
Bodsy’s Brake Bible  
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 2 of 36 
 
Change Record 
DATE Revision Update Notes Made By 
May 2010 1.2 Amended Torque Figures and bolt sizes, cleaned up photo 
areas. Updated text. 
Ian Bodsworth 
June 2010 1.2a Re-worded EPB adjust procedure, updated EBP Allen key size. 
Added Change record 
Ian Bodsworth 
July 2010 1.3 Updated Tool List, inserted Tool/Job Matrix, added EPB 
change instructions, added jacking point pics, added Brake 
Pad Wear Sensor replacement & pics. +minor Word changes 
Ian Bodsworth 
August 2010 1.4 Updated Picture pointers, added Brake Bleed procedure 
(awaiting Pics). Added Jack Adapter Info & spreader Plate 
advice under Jack in hot weather.  
Ian Bodsworth 
Jan 2011 1.5 Removed Loctite Instruction on Torx50 screw when changing 
disks. Fitting ‘Sticky’ side of some OEM pads instructions 
updated. Added EPB Adjuster direction information. Section 
Link updated. Updated Remove Pads before Shim 
instructions. Added a few more pointers. 
Ian Bodsworth 
June 2011 1.6 Clarified EPB shoe instructions & corrected references to 
other sections. Added paypal donations information 
(requested by users of the guide.) Internationalised wheel 
location references by removing UK based reference to 
OS/NS, replaced with physical Front Left or Front Right 
descriptions. 
Ian Bodsworth 
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
    
   
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 3 of 36 
 
Table of Contents 
1. Introduction ............................................................................................................. 4 
2. Tools that may be required .......................................................................................... 5 
3. Jacking Points and Axle Stands ..................................................................................... 7 
4. How to change the Brake Pads - Front .......................................................................... 10 
5. How to change the Brake Pads – Rear............................................................................ 14 
6. How to change the Brake Pad Sensors – Front and Rear ..................................................... 18 
7. How to change the Brake Disks – Front .......................................................................... 20 
8. How to change the Brake Disks – Rear ........................................................................... 23 
9. How to adjust the Electronic Park Brake........................................................................ 27 
10. How to fit new EPB Shoes ....................................................................................... 29 
11. How to Bed in new EPB shoes .................................................................................. 32 
12. How to replace the brake fluid and Bleed the braking system ........................................... 33 
 
   
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 4 of 36 
 
1. Introduction 
Welcome to Bodsy’s Brake Bible. The aim of this ‘Bible’ is to provide a single area for all 
information relating to the servicing and maintenance of your Discovery 3 2,7 TDv6 braking 
system. It can be used as a basis for the V6 and V8 Petrol as well as the 3.0l TDv6, but I cannot 
guarantee it will be exactly right for those variants as I have not used this on those models. If 
you have used this guide on those models and have any updates we could use (inc pics) then 
please e-mail them to me [email protected] and I will update this accordingly. 
Please note that these are guidelines only and you should ensure that you are competent in 
the use of the tools required and take the necessary safety precautions. If you have any doubt 
of your competence, please contact your nearest Land Rover dealer or Land Rover 
independent garage who will be pleased to carry out this work for you. 
Neither the author nor Disco3Club/Disco4Club can accept any responsibility for any accidents 
or injuries sustained whilst undertaking the work depicted in this bible.  
All of the photos (unless otherwise indicated) are from my Discovery 3 MY07 TdV6 HSE. 
Further technical information is available from Land Rover’s subscription services TOPIx (ex-
GTR) website, which can be found here:-  
http://topix.landrover.jlrext.com/topix/vehicle/lookupForm 
http://www.landrovertechinfo.com/ 
I acknowledge the assistance of members of the Disco3 forum and Land Rover® TOPIx/GTR  
for the initial guidance and advice before I commenced this guide which supersedes my 
previous collection of posts and other information. 
   
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 5 of 36 
 
2. Tools that may be required 
Please find a list below of the tools that you will need to have in order to complete the tasks set 
out below.  
 
I’ll be looking to add OEM and Non OEM brake part numbers & rough costs to this schedule in the 
future. (Thanks Bruce)  
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 6 of 36 
 
 
All torque settings contained within this ‘bible’ are manufacturers recommended settings.  
Optional additions to the tool kit are:- 
1) Regular cups of tea/coffee 
2) Box of plasters for grazed knuckles 
3) A suitably sized swear box, depending on a combination of a) location b) weather c) 
temperature d) ‘help’ by young children/dog/neighbours    
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 7 of 36 
 
3. Jacking Points and Axle Stands 
The standard jack that comes with the Discovery 3 or 4, is widely regarded as ‘not very good’. If you are going 
to do any work on your vehicle that requires raising the chassis, then we would recommend that you purchase 
or borrow a suitable trolley jack. 
The Discovery 3 / 4 weighs in excess of 2.7 tonnes, so you need to ensure that you have a jack that is capable 
of supporting both the weight of the vehicle and the height 
that is required. NOTE: If jacking in hot weather on tarmac, 
place a suitable sized piece of wood under the jack to stop it 
digging into the softer tarmac. 
Most hydraulic jacks are suited to standard sized cars. Your 
Discovery has a height range that requires a jack ideally 
capable of lifting 520mm. 
One popular jack is the Clarke CTJ3000G, it is a heavy duty 
trolley jack available (at time of creation) at Machine Mart  
http://www.machinemart.co.uk/shop/product/details/ctj3000
g-3-tonne-professional-garage-j 
Beware, there is also a CTJ3000QL which is a quick lift version 
of the above. There have been reports of this model twisting under load when used on a Discovery 3 or 4. 
There is a machined adapter that can be bought on the WWW that fits the CTJ3000G, which makes it easier to 
locate in the LR jacking holes. Search for “Jack Adapter Clarke CTJ3000G Manufacture”  
There are specific jacking points underneath your car, DO NOT JACK ON YOUR AIR SUSPENSION COMPRESSOR 
COVER or on the long air compressor tank. You will damage it beyond repair. 
Once you have jacked the car up, ensure that you use suitable axle stands to secure the car.  I have these, 
rated at 6T (pair) and more than sufficient height available. 
But others are available, 
such as these  
http://www.machinemart
.co.uk/shop/product/deta
ils/cax-6tbc-6-ton-axle-
stands 
Others are available, but 
the sturdier the better. 
  
Ensure that your vehicle is securely supported on axle stands  
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 8 of 36 
 
before undertaking any work underneath it. Ensure that any wheels remaining in contact with the ground are 
securely chocked to avoid any unnecessary movement. If removing Wheels, loosen the wheel nuts before 
jacking off the ground. 
WARNING: Always chock the wheels which are not to be raised.  
 
 
 One front wheel - position lifting pad of hydraulic jack beneath longitudinal member on the side to be 
raised at Point A  
 One rear wheel - position lifting pad of jack beneath longitudinal member on the side to be raised at 
Point B  
 Front and rear wheels - ONE SIDE - position lifting pad of jack beneath longitudinal member on the 
side to be raised at Point C  
NOTE:  
  Point C is in line with number 3 body mounting.  
 
 
 
With vehicle at desired height, position axle stand(s) beneath longitudinal members and adjacent to the lifting 
pad of the jack at appropriate point(s) D. 
  CAUTION: Position suitable material between axle stands and longitudinal members to prevent 
damage to the longitudinal members.  
 
Carefully lower jack until vehicle rests on axle stands.   
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 9 of 36 
 
Pictures below show the position of the LandRover supplied jack. I DO NOT RECOMMEND THAT YOU 
USE THIS JACK EXCEPT IN AN EMERGENCY. 
In my opinion, this jack is not suitable for regular (or even irregular!) use  on your Discovery3. 
This image is on the 
rear passenger side.
  
You can see the 
hole that the jack 
would sit into at the 
top of the jack. (the 
Clarke adapter also 
fits into these 
holes.)  
 
DO NOT jack on the Air Compressor Receiver Tank OR the Air compressor cover. 
See use of Axle Stand for Safety. 
Before raising the wheels off the ground, use a 22mm socket 
and a breaker bar to ‘break’ the wheel nuts on the wheels that 
will be lifted in the air. i.e. loosen the wheel nuts  by one half 
turn. Then, once the car is securely raised, you can continue to 
remove the wheel nuts using the 22mm socket. If you have a 
locking wheel nut, please ensure that you have found this 
before commencing work. 
When you have finished your work, re-fit the road wheels and 
secure the bolts. When you have lowered the car back on the ground, you will need to ensure that the road 
wheel bolts are tightened using the Torque wrench, set to 140Nm.  
LR Jack pictures kindly supplied by Beau. 
  
 
   
						

							©  Copyright  Ian  Bodsworth  2011.  All  descriptions  and  photo’s  contained  within  remain  the  property  of  the  Author. 
Commercial images of products with copyrights acknowledged. E&OE. - Created by Bodsy – Disco3Club  
    Page 10 of 36 
 
4. How to change the Brake Pads - Front  
Ensure that your vehicle is securely supported on axle stands before undertaking any work underneath it. 
Ensure that any wheels remaining in contact with the ground are securely chocked to avoid any unnecessary 
movement. 
Change Front Brake Pads  (See page 5 for tool matrix)
Pliers 
Brake Cleaner 
Spanners, 13mm, 17mm 
Copper Grease 
Optional Ratchet 
 
Socket 13mm 
Torque Wrench 
 
The Discovery 3 has a Dual piston calliper brake system for the Front. It relies on hydraulic pressure from the 
braking system to push brake Pads onto the rotating Brake Disk. Over time, the Brake pads will wear down, 
eventually causing a loud scrapping noise as the brake pad backing plate grinds into the steel disk. If you have 
reached this point, then in all likelihood, you will need to replace the Brake disks as well as the pads. 
The front LEFT side disk also has a brake wear sensor. If you have NOT broken through this sensor, then it can 
be safely re-used. Otherwise you need to ensure you have a replacement at the time of fitting. 
Jack the car up (see Axle Stands & Jacking Points) Remove the front road wheels. 
Once you have the road wheels removed, then you can remove 
the Brake pad wear sensor. (Front Passenger Side) 
Use a pair of pliers to carefully extract the sensor. You may find 
that the brass contact in the sensor is also removed. Providing 
that you don’t lose it or it doesn’t ping off into a deep hidden 
crevice, then it should be able to be easily re-fitted. 
You should pull the sensor directly backwards until it is 
removed. 
Here you can see the sensor without the brass contact (which has remained on 
the brake pad). 
 
Here you can see the brass contact which needs to be 
re-fitted or the whole sensor replaced.