1999 LAND ROVER DEFENDER Workshop Manual

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CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01.01
Remove
1.Remove gearbox assembly.See MANUAL
GEARBOX, Repair.
2.Restrain flywheel.
3.Working in sequence, loosen 6 nuts securing
clutch cover to flywheel.
4.Remove clutch cover and clutch plate.
Refit
5.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
6.Position clutch drive plate to flywheel with
’gearbox side’ facing towards gearbox.
7.PositionLRT-12-152alignment tool through
drive plate into spigot bearing in crankshaft.8.Fit clutch cover and locate on dowels.
9.Position clutch cover nuts and tighten in diagonal
sequence to25 Nm (18 lbf.ft).
10.Fit gearbox assembly.See MANUAL
GEARBOX, Repair.
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33CLUTCH
2
REPAIR BEARING - CLUTCH RELEASE
Service repair no - 33.25.12
Remove
1.Remove gearbox assembly.See MANUAL
GEARBOX, Repair.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch release
fork.
Refit
4.Clean release fork.
5.Examine clutch release fork pivot points for
wear.
6.Apply a smear of Molybdenum disulphide grease
to release fork pivot points.
7.Fit retaining clip ensuring it locates over pivot
point washer.
8.Fit bolt and tighten to10 Nm (7 lbf.ft).
9.Clean release bearing and bearing sleeve
mating faces.
10.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
11.Fit release bearing and secure with retaining
peg.
12.Fit gearbox assembly.See MANUAL
GEARBOX, Repair.CLUTCH - MASTER CYLINDER LH DRIVE
Service repair no - 33.20.01
Remove
1.Remove 3 screws securing closing panel to
lower’A’post.
2.Release closing panel sufficient to gain access
to clutch and brake pedal bracket bolts.
3.Remove clutch pedal rubber.
4.Remove 12 bolts securing clutch and brake
pedal brackets to body.
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CLUTCH
3
REPAIR
5.Disconnect multiplug from clutch pedal sensor.
6.Disconnect muliplug and harness clip from pedal
bracket.
7.Position cloth to collect fluid spillage.
8.Loosen pipe union, release pipe and plug pipe
and master cylinder.
9.Move brake master cylinder assembly aside and
lift out clutch master cylinder assembly.
10.Remove 6 screws, remove pedal box top cover
and discard gasket.
11.Remove nut securing push rod to clutch pedal
trunnion.
12.Remove 2 bolts and remove clutch master
cylinder from pedal bracket.
13.Remove clutch pedal sensor and pipe union
from master cylinder and discard sealing
washers.Refit
14.Clean sensor and pipe union.
15.Fit clutch pedal sensor and pipe to master
cylinder using new sealing washers.
16.Position master cylinder to pedal bracket and
align push rod to pedal trunnion.
17.Fit bolts and nuts and secure master cylinder to
pedal bracket.
18.Fit nut securing push rod to clutch pedal trunnion
but do not tighten nut at this stage.
19.Move brake master cylinder aside and position
clutch master cylinder assembly.
20.Clean clutch pipe union.
21.Align pipe and tighten union.
22.Connect multiplug to clutch pedal sensor.
23.Tighten bolts securing clutch pedal and brake
pedal brackets to body.
24.Fit clutch pedal rubber.
25.Position closing panel and tighten screws to
lower’A’post.
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33CLUTCH
4
REPAIR Clutch pedal setting
1.Loosen both locknuts on master cylinder push
rod.
2.Check distance from lower edge of clutch pedal
to floor. Correct measurement is 140 mm (5.50
in) without floor mat.
3.Adjust pedal stop to obtain correct setting.
4.Adjust master cylinder push rod to obtain
approximately 1.5 mm (0.06 in) free play
between push rod and master cylinder piston.
5.Tighten push rod locknuts.
6.Check operation of clutch pedal and ensure that
there is minimum of 6 mm (0.25in) of free play
before pressure is felt.
7.Fit pedal box top cover and multiplug bracket
using a new gasket and secure with screws.
8.Connect multiplug and harness clip to pedal
bracket.
9.Bleed clutch hydraulic system.See
Adjustment.CYLINDER - CLUTCH SLAVE
Service repair no - 33.35.01
Remove
1.Disconnect pipe from slave cylinder.
CAUTION: Plug the connections.
2.Position container to catch spillage.
3.Remove 2 bolts securing slave cylinder to bell
housing.
4.Withdraw slave cylinder from bell housing and
push rod.
Refit
5.Clean ends of pipes, bell housing and slave
cylinder mating faces.
6.Lubricate end of push rod with Molybdenum
disulphide gease.
7.Locate slave cylinder to push rod and bell
housing.
8.Fit bolts and tighten to25 Nm (18 lbf.ft).
9.Connect clutch pipe to slave clyinder.
10.Bleed clutch system.See Adjustment.
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37 - MANUAL GEARBOX
CONTENTS
Page
ADJUSTMENT
SPRINGS - GEAR LEVER BIAS 1..........................................................................
GEARBOX OIL - DRAIN AND REFILL 2.................................................................
REPAIR
COVER - FRONT - RESEAL AND FIT NEW INPUT SHAFT OIL SEAL 1..............
LEVER - GEAR CHANGE 3....................................................................................
MECHANISM AND HOUSING - GEAR SELECTOR 4...........................................
MECHANISM AND HOUSING - GEAR SELECTOR - RESEAL 6..........................
GEARBOX 7...........................................................................................................
SWITCH - REVERSE LIGHT 12.............................................................................
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MANUAL GEARBOX
1
ADJUSTMENT SPRINGS - GEAR LEVER BIAS
Service repair no - 37.16.26
Check
NOTE: The purpose of this adjustment is
to set both bolts so that the bias spring
legs apply equal pressure on both ends of
the gear lever cross pin when 3rd or 4th gear is
engaged. This will ensure that when the gear lever
is in neutral, the gear change mechanism is
automatically aligned for 3rd or 4th gears.
1.Remove gear lever knobs.
2.Release and remove gear lever gaiter.
3.Select 3rd or 4th gear.
4.Adjust the two adjusting screws until both legs of
the spring are approximately 0.5 mm (0.02 in)
clear of cross pin in the gear lever.
5.Apply a light load to the gear lever in a RH
direction and adjust the LH adjusting screw
downwards until the LH spring leg just makes
contact with the cross pin.
6.Repeat the same procedure for the RH adjusting
screw.
7.Lower both adjusting screws equal amounts until
the radial play is just eliminated. Tighten lock
nuts.
8.Return gear lever to neutral position and move
gear lever across the gate several times. The
gear lever should return to the 3rd and 4th gate.
9.Fit gear lever gaiter.
10.Fit gear lever knobs.
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