2002 LAND ROVER DISCOVERY clutch

CLUTCH - TD5
33-1-14 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 - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - TD5
REPAIRS 33-1-15
Bearing and lever - clutch release
$% 33.25.12
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release lever.
Remove retaining clip and 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
release bearing 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 - Diesel.
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 - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - TD5
33-1-16 REPAIRS

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-1
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CLUTCH - V8 DESCRIPTION AND OPERAT ION

CLUTCH - V8
33-2-2 DESCRIPTION AND OPERATION
Clutch components

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-3
1Brake/clutch reservoir
2Connecting hose
3Bolt 2 off
4Master cylinder
5Clutch pedal
6Gearbox housing
7Primary driveshaft
8Bolt 2 off
9Slave cylinder
10Bleed nipple
11Pressure plate
12Drive plate
13Flywheel
14Metal hydraulic pipes
15Ball spigot
16Clutch release bearing sleeve
17Bolt 2 off
18Pivot washer
19Release lever
20Release bearing
21Retaining clip
22Bolt
23Bolt

CLUTCH - V8
33-2-4 DESCRIPTION AND OPERATION
Hydraulic operation

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-5
1Brake/clutch reservoir
2Fluid supply pipe
3Hydraulic feed pipe
4Master cylinder
5Piston
6Clutch pedal
7Primary driveshaft
8Engine crankshaft
9Drive plate
10Flywheel
11Ring gear
12Cover - Pressure plate
13Leaf spring
14Retractor clip
15Diaphragm
16Release bearing
17Ball spigot
18Release bearing sleeve
19Release lever
20Slave cylinder
21Piston
22Bleed nipple