1995 LAND ROVER DISCOVERY Workshop Manual

33CLUTCH
2
REPAIR BLEED HYDRAULIC SYSTEM
Service repair no - 33.15.01
Procedure
NOTE: During bleed procedure, keep fluid
reservoir topped up to avoid introducing
air to system. For hydraulic fluid
recommendations.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Recommended
Lubricants and Fluids
1.Attach suitable tubing to slave cylinder bleed
screw.
2.Place free end of tube in a glass jar containing
clutch fluid.
3.Loosen bleed screw.
4.Pump clutch pedal, pausing at end of each
stroke, until fluid from tubing is free of air.
Keeping free end of tube below surface of fluid.
5.Hold clutch pedal down, tighten bleed screw.
6.Top up fluid reservoir.MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate hydraulic fluid from system.
2.Disconnect fluid pipe at master cylinder. Plug
master cylinder fluid port and seal end of
hydraulic pipe to prevent ingress of foreign
matter.
3.Lower fascia fuse box panel.
4.Remove master cylinder fixings.
5.Remove retaining washer and clevis pin from
push rod and clutch pedal.
6.Remove master cylinder.

CLUTCH
3
REPAIR Refit
7.Fit the master cylinder and fixings.
8.Fit push-rod to pedal and retain with clevis pin
and washer.
9.Raise fasica fuse box panel.
10.Fit fluid pipe to master cylinder.
11.Bleed system.
See Bleed Hydraulic System
RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 Manual Gearbox
2.Remove clutch slave cylinder.See Slave
Cylinder
3.Withdraw retainer staple.
4.Withdraw bearing and sleeve. If required, press
bearing off sleeve. Fit replacement bearing with
domed face outwards from sleeve.
5.Remove spring clip and fixings.
6.Withdraw release lever assembly.
Refit
7.Smear pivot with grease and fit release lever and
retain with spring clip and bolt.
8.Smear release bearing sleeve inner diameter
with molybdenum disulphide base grease.
9.Reverse removal procedure. 1 to 4.

33CLUTCH
4
REPAIR SLAVE CYLINDER
Service repair no - 33.35.01
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Evacuate clutch system fluid at slave cylinder
bleed valve.
2.Disconnect fluid pipe.
3.Remove two securing bolts and withdraw slave
cylinder and backing plate.
4.If dust cover is not withdrawn with slave cylinder,
withdraw it from bell housing.
Refit
5.Withdraw dust cover and backing plate from
slave cylinder.
6.Coat both sides of backing plate with Hylomar
P232M waterproof jointing compound.
7.Locate backing plate and dust cover in position
on slave cylinder.
8.Fit slave cylinder, engaging push-rod through
centre of dust cover and with bleed screw
uppermost.
9.Reconnect fluid pipe.
10.Replenish and bleed clutch hydraulic system.
11.Check for fluid leaks with pedal depressed and
also with system at rest.

CLUTCH
5
REPAIR RENEWING HYDRAULIC DAMPER - Tdi
Service repair no - 33.15.05
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Remove the pipe between the slave cylinder and
damper.
2.Disconnect the hydraulic hose from the damper.
3.Remove the two bolts securing the damper to
the bracket and remove the damper.
Refit
4.Fit the damper to the bracket and tighten the two
bolts.
5.Connect the flexible hose to the damper.
6.Fit the pipe to the slave cylinder and to the
damper and tighten the unions.
7.Bleed the hydraulic system.

CLUTCH
1
OVERHAUL MASTER CYLINDER
Service repair no - 30.20.07
1.Remove master cylinder.
See Repair, Master
Cylinder
Disassemble
2.Pull back and remove rubber sealing boot from
pushrod.
3.Depress push-rod and extract circlip.
4.Withdraw push-rod assembly.
5.Withdraw piston assembly.
6.Withdraw retainer and spring.
7.Remove two piston seals and piston washer.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid. Dry, using a lint-free cloth.
9.Examine cylinder bore and piston, ensure they
are smooth to touch with no corrosion, score
marks or ridges. If in doubt, fit new components.
10.Fit new seals and rubber boot. These items are
all included in master cylinder overhaul kit.
11.Ensure that feed and by-pass ports are not
obstructed.
12.Ensure reservoir cap vent is clear.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt. Lubricate
cylinder bore and rubber seals with new
hydraulic fluid before assembly.
13.Fit a new piston washer and thinner of two piston
seals, lip last, over piston nose, up against
drilled piston head. Fit thicker seal into piston
groove with lip facing towards seal at opposite
end.
14.Insert spring and retainer into master cylinder
bore.
15.Insert piston and seal assembly, ensuring that
seal lips do not bend back.
16.Reverse 3 and 4, correctly locating circlip.
17.Stretch new rubber boot over push-rod, pack
with rubber grease. Fit securely into locating
groove.
18.Operate push-rod several times to ensure free
movement of internal components.
19.Fit master cylinder.

33CLUTCH
2
OVERHAUL SLAVE CYLINDER
Service repair no - 33.35.07
Overhaul
1.Remove slave cylinder.
See Repair, Slave
Cylinder
Disassemble
2.Withdraw rubber boot.
3.Withdraw push-rod.
4.Remove circlip.
5.Extract piston and seal assembly, applying low
pressure air to fluid inlet if necessary.
6.Withdraw spring.
7.Remove bleed valve.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid, and dry using lint-free cloth.
9.Examine cylinder bore and piston which must be
free from corrosion, scores and ridges.
10.Replace seal and rubber boot using appropriate
repair kit.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt.
11.Fit bleed valve. Do not overtighten.
12.Lubricate seals, piston and bore using new
hydraulic fluid.
13.Fit seal into piston groove, lip of seal towards
fluid inlet end of cylinder.
14.Enter piston assembly, spring first, into cylinder
bore. Ensure that seal lip does not fold back.
15.Secure with circlip.
16.Fill rubber boot with rubber grease.
17.Reverse removal procedure. 1 to 3.

CLUTCH
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Clutch pipes
Master cylinder union 15.................................................................................
Pipe joint 15....................................................................................................
Pipe to damper 15...........................................................................................
Pipe out of damper 15.....................................................................................
Pipe to jump hose 15......................................................................................
Jump hose to pipe 15......................................................................................
Pipe to slave cylinder 15.................................................................................

R380
1
DESCRIPTION AND OPERATION MANUAL TRANSMISSION
Description
The all synchromesh five speed manual gearbox unit,
is married to a LT230T two speed transfer gearbox.
All the gears including reverse run on needle roller
bearings and the main, layshaft and primary shafts
are supported by tapered roller bearings.The whole of the geartrain is lubricated through
drillings in the shafts, supplied by a low pressure
pump driven from the rear of the layshaft. The gear
change has a single rail selector and spool type
interlock. The main and transfer gearboxes ventilate
through nylon pipes, which terminate high up in the
engine compartment to prevent water entry when the
vehicle is operating in adverse conditions.
1. Mainshaft 1st gear
2. Mainshaft 2nd gear
3. Mainshaft 3rd gear
4. Primary input shaft
5. Mainshaft 5th gear
6. Layshaft
7. Mainshaft
8. Lubrication pump9. Drain plug
10. Ventilation pipe
11. Single rail gear shift
12. 1st/2nd synchromesh
13. Oil seals
14. 3rd/4th synchromesh
15. 5th gear synchromesh