1999 LAND ROVER DISCOVERY Workshop Manual

CLUTCH - V8
ADJUSTMENTS 33-2-11
ADJUST ME NTS
Clutch hydraulic system - bleed
$% 33.15.01
CAUTION: Ensure the fluid in the reservoir is
maintained between the minimum and maximum
levels throughout the bleed procedure using new
brake fluid.
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Bleeding
1.Top up reservoir.
2.Raise the front of the vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Connect tube to bleed screw on clutch slave
cylinder and submerge free end in a clear
container containing brake fluid.
4.Loosen bleed screw, then apply steady
pressure to the clutch pedal, depressing it
through its full stroke. Allow the pedal to return
unassisted.
5.Repeat the procedure until a flow of clean, air-
free fluid is purged into the container.
6.Hold the pedal to the floor and tighten the
clutch bleed screw to 9 Nm (7 lbf.ft).
7.Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8.Remove stands and lower the vehicle.

CLUTCH - V8
REPAIRS 33-2-13
REPAIRS
Clutch assembly
$% 33.10.01
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in diagonal sequence, progressively
loosen 6 bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Renew all worn or damaged components.Refit
1.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
2.Fit LRT-12-001 to spigot bearing in crankshaft.
3.Fit clutch plate onto LRT-12-001, ensure side
marked 'flywheel side' is against flywheel.
4.Fit clutch cover and locate on dowels.
5.Fit clutch cover bolts and progressively tighten,
in diagonal sequence shown, to 40 Nm. (30
lbf.ft).
6.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.

CLUTCH - V8
33-2-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder. Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
REPAIRS 33-2-15
Bearing and lever - clutch release
$% 33.25.12
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release lever.
Remove retaining clip and remove clutch
release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip, ensuring it locates over clutch
release lever pivot point washer. Fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Slave cylinder
$% 33.35.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-1
MANUAL GEARBOX - R380 DESCRIPTION AND OPERAT ION
R380 gearbox