1996 LAND ROVER DEFENDER ECU

33CLUTCH
2
REPAIR MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All hose and pipe connections and
joints should be tightened to
15 Nm (11
lbf/ft).
Remove
1.Drain 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 dirt.
3.On RH drive vehicles, unclip air cleaner retaining
straps, disconnect bottom hose, and move
assembly aside.
4.From inside vehicle, remove fibre board closing
panel above pedals.
5.Remove 6 bolts securing pedal bracket to
bulkhead.
6.Remove screw securing speedometer cable
retaining bracket to top of pedal bracket.
7.Move pipework and cables aside and lift out
pedal bracket, complete with master cylinder,
turn through 90°to ensure pedal clears aperture
in bulkhead.8.Remove 6 screws and detach pedal box top
cover and gasket.
9.Remove nut and washer securing master
cylinder push rod to clutch pedal trunnion.
10.Remove 2 nuts and bolts and withdraw master
cylinder from pedal bracket.
Refit
11.Fit master cylinder to pedal bracket, engaging
cylinder push rod through pedal trunnion.
12.Secure push rod to pedal trunnion.
13.Apply sealant to mating surfaces and fit pedal
bracket to engine bulkhead.
14.Connect fluid pipe to master cylinder.
15.Bleed clutch hydraulic system
See Bleed
hydraulic system
.
16.Check and adjust clutch pedal and master
cylinder setting
See Adjustment, Clutch pedal
and master cylinder setting
.
17.Fit top cover and gasket to pedal bracket.
18.On RH drive vehicles, refit air cleaner.

CLUTCH
3
REPAIR CLUTCH PEDAL
Service repair no - 33.33.02
Remove
1.Remove pedal bracket assembly and master
cylinder
See Master cylinder.
2.Release return spring from clutch pedal.
3.Using a suitable punch, drift out securing pin and
withdraw pedal pivot shaft.
4.Withdraw clutch pedal, complete with trunnion
and bush.
5.If necessary remove pivot bushes.
6.Examine components for wear and damage,
renew as necessary.
NOTE: If new pedal pivot bushes are
required they must be reamed to 16 mm
(0.625 in).
Refit
7.If removed, fit trunnion bush and trunnion to
clutch pedal. Lubricate components with general
purpose grease on assembly.
8.Fit pedal to bracket, insert pivot shaft and secure
with new pin.
9.Fit pedal return spring.
10.Fit master cylinder and pedal bracket assembly
See Master cylinder.
11.Adjust clutch pedal and master cylinder setting
See Adjustment, Clutch pedal and master
cylinder setting
.

MANUAL GEARBOX
1
FAULT DIAGNOSIS R380 GEARBOX
Symptom - Gear jumps out of engagement (any
forward gear)
1.Check condition and security of transmission
and engine mountings.
2.Check in situ, gear lever and selector
adjustments
See Adjustment, Gear change
lever bias spring - adjust
andSee
Adjustment, Fifth gear stop screw adjust
.
3.In situ, remove gearshift and check selector rail
yoke security.
Also check selector detent spring tension and
both spool retainers.
Suspect internal fault, see Overhaul Manual.
4.Check action/operation of main selector rail and
forks.
5.Check condition of synchromesh and gear dog
teeth.
6.Check main and layshaft end floats bearings and
adjustments.
7.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Reverse gear only jumps out of
engagment
1.Check condition and security of transmission
and engine mountings.
2.Check in situ, gear lever and selector
adjustments
See Adjustment, Gear change
lever bias spring adjust
andSee Adjustment,
Fifth gear stop screw adjust
.
3.In situ, remove gearshift and check selector rail
yoke security.
Also check selector detent spring tension and
both spool retainers.
Suspect internal fault, see Overhaul Manual.
4.Check action/operation of main selector rail and
reverse lever.
5.Check condition of reverse gear, angled
bearings and shaft.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.Symptom - Excessive force required to engage or
change gear, vehicle stationary or moving.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.In situ, lubricate gear mechanism, and check
selector adjustments
See Adjustment, Gear
change lever bias spring - adjust
andSee
Adjustment, Fifth gear stop screw adjust
.
3.In situ, remove gearshift and check selector rail
is free and that the yoke is secure. Also check
selector detent spring tension and both spool
retainers.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh unit or baulk rings
on affected gears, see Overhaul Manual.
Symptom - Noisy gear engagement, vehicle
stationary
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults
.
Symptom - Noisy gear selection, vehicle moving.
1.Confirm that clutch operation is satisfactory.
2.Establish which gear/gears is causing noise.
3.Check lubricant specification and level, if low do
not top up at this stage.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh, see Overhaul
Manual.
5.Check condition of synchromesh unit, springs
and cones for distortion and wear. Also check
dog teeth for damage and cone mating surface
on gear for signs of overheating.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Noise from gearbox in neutral, which
changes tone or becomes worse when clutch is
depressed,
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults
.
Symptom - Noise from gearbox in neutral, which
disappears when clutch is depressed.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.Drain lubricant and check for contamination or
metal particles.
Suspect worn bearings on layshaft, primary shaft
or front of main shaft, see Overhaul Manual.

MANUAL GEARBOX
1
ADJUSTMENT GEAR CHANGE LEVER BIAS SPRING - ADJUST
Service repair no - 37.16.26
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Fit gear lever and select 3rd or 4th gear.
7.Slacken adjustment screw locknuts.
8.Adjust screws until both legs of bias springs are
approximately 0.5mm clear of gear lever cross
pin.
9.Apply a slight load to gear lever in a LH direction
and adjust RH screw downward until RH spring
leg just makes contact with cross pin.
10.Repeat procedure for LH adjustment screw.
11.Lower both adjustment screws equal amounts
until radial play is eliminated.
12.Tighten locknuts.
13.Return gear lever to neutral position and rock
across gate several times. The gear lever should
return to 3rd and 4th gate.
14.Remove gear lever.
15.Fit insulation pad.
16.Locate gaiter over lower lever and bias springs.
17.Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
18.Fit gear lever cover.
19.Fit gear lever and transfer box lever knobs.

37MANUAL GEARBOX
2
ADJUSTMENT FIFTH GEAR STOP SCREW - ADJUST
Service repair no - 37.16.67
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Remove tunnel carpet.
7.Remove retaining screws and release fuse box
cover.
8.Remove 2 screws and release fuse box from
bulkhead to assist next operation.
9.Remove 16 screws securing tunnel cover to
vehicle body.
10.Manouvre tunnel cover to clear handbrake lever
and remove from vehicle.
11.Fit gear lever and knob and select reverse gear.

MANUAL GEARBOX
3
ADJUSTMENT
12.Slacken stop screw locknut.
13.Apply light pressure to gear lever towards LH
side and turn screw clockwise until it abuts yoke.
14.Turn screw anti-clockwise until 25 mm freeplay
is felt at gear lever knob. Ensure 5th gear can be
engaged.
15.Tighten stop screw locknut.
16.Check that all other gears are selectable.
17.Remove gear lever.
18.Manouvre tunnel cover into position and secure
with 16 screws.
19.Fit fuse box and cover.
20.Fit tunnel carpet.
21.Fit insulation pad into tunnel aperture.
22.Locate gaiter over lower lever and bias springs.
23.Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
24.Fit gear lever cover.
25.Fit gear lever and transfer box lever knobs.

MANUAL GEARBOX
1
REPAIR REV: 05/99 R380 GEARBOX
Service repair no - 37.20.51
Remove
The R380 gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
support plateLRT-99-007.
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
.
1.Install vehicle on a ramp.
2.Disconnect battery.
3.Remove gearbox carpet.
4.Remove gear lever and transfer box lever knobs.
5.Remove gear lever cover.
6.Remove nut and washer securing gear lever.
7.Mark gear lever spline setting and remove lever
and gaiter from the splined lower gear lever.
8.Release insulation pad from tunnel cover and
gear levers and remove.
9.Select low range on transfer box lever to prevent
lever from fouling tunnel when removing
gearbox.

37MANUAL GEARBOX
2
REPAIR
10.Remove 3 trim studs and lift up handbrake
gaiter.
11.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
12.Drain cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
13.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
14.Slacken retaining clip and disconnect radiator
top hose at thermostat housing.
15.Slacken retaining clip and disconnect intake
hose at induction manifold. If EGR system is
fitted, slacken 2 retaining clips and disconnect
intake hose at intercooler.
16.Slacken retaining clip and disconnect hose at
turbocharger.
17.Remove bolt securing transmission breather
pipe clip to rear of engine.
18.Release breather pipes.
19.Release ties securing gearbox harness to
breather pipes.
20.Raise vehicle on ramp.
21.Position a suitable container under transmission
and drain main gearbox and transfer box
See
MAINTENANCE , Under vehicle maintenance
.
22.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
23.Remove 4 nuts and disconnect propeller shaft
from transfer box.