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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
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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.
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.............................................................................
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.
37MANUAL GEARBOX 2 ADJUSTMENT GEARBOX OIL - DRAIN AND REFILL Service repair no - 37.24.01 Drain 1.The oil should be drained when the gearbox is warm and the vehicle is standing on a level surface. WARNING: Observe due care when draining gearbox as oil can be very hot. 2.Raise vehicle on ramp. 3.Position container to collect oil. 4.Clean area around filler/level plug. 5.Remove filler/level plug. NOTE: Later gearboxes: Use No. 55 Torx bit to remove filler/level plug. 6.Remove gearbox drain plug and discard sealing washer.Refill 1.Clean gearbox drain plug and fit new sealing washer. 2.Fit gearbox drain plug and tighten to50 Nm (36 lbf.ft). 3.Fill gearbox with correct grade of oil.See LUBRICANTS, FLUIDS AND CAPACITIES, Information. 4.Apply Loctite 290 to the filler/level plug and tighten to30 Nm (22 lbf.ft). 5.Remove fluid container. 6.Lower vehicle on ramp.
MANUAL GEARBOX 1 REPAIR COVER - FRONT - RESEAL AND FIT NEW INPUT SHAFT OIL SEAL Service repair no - 37.12.33.01 Remove 1.Remove gearbox.See this Section. 2.Remove retaining peg and remove release bearing. 3.Remove bolt securing clutch release fork, remove retaining clip and remove clutch release fork. 4.Remove 2 bolts securing release bearing sleeve, remove bearing sleeve. 5.Remove 6 bolts securing clutch housing, remove housing. 6.Remove and discard 6 bolts securing front cover, remove cover.
37MANUAL GEARBOX 2 REPAIR 7.Using a soft metal drift, carefully remove input shaft front bearing track from front cover. CAUTION: Take care not to damage bearing track, if track is damaged, it will be necessary to fit a new input shaft front bearing. 8.Remove input shaft oil seal from front cover; discard oil seal. Refit 9.Using a suitable solvent clean seal recess, front cover and gearbox mating faces; clean threads of bolts and bolt holes. 10.Clean bearings and bearing races. 11.Lubricate a new oil seal with gearbox oil. 12.Fit oil seal using a suitable mandrel. 13.Fit input shaft front bearing track using a press and suitable mandrel. 14.Apply sealant, Part No. STC 4404 to front cover. 15.Position front cover, apply Loctite 290 to threads of bolts; fit new bolts and tighten by diagonal selection to25 Nm (18 lbf.ft). 16.Clean clutch housing mating faces, dowels and dowel holes. 17.Position clutch housing, fit bolts and tighten by diagonal selection to75 Nm (55 lbf.ft). 18.Clean bearing sleeve mating faces, dowel and dowel holes. 19.Position bearing sleeve, fit bolts and tighten to 25 Nm (18 lbf.ft). 20.Examine clutch release fork pivot points for wear and replace as required. 21.Apply a smear of Molybdenum disulphide grease to pivot points and position release fork. 22.Fit retaining clip ensuring it locates over pivot point washer, fit bolt and tighten to10 Nm (7 lbf.ft).23.Clean release bearing and bearing sleeve mating faces. 24.Apply smear of Molybdenum disulphide grease to release bearing sleeve. 25.Fit release bearing and secure with retaining peg. 26.Fit gearbox.See this Section.
MANUAL GEARBOX 3 REPAIR LEVER - GEAR CHANGE Service repair no - 37.16.04 Remove 1.Remove gear lever knob. 2.Release and remove gear lever gaiter(s). 3.Remove nut securing upper gear lever to lower gear lever. 4.Remove upper gear lever from lower gear lever. 5.Using a suitable piece of tubing fitted over end of bias spring, release both ends of bias spring from ball pins. 6.Remove bolt and special washer securing gear lever to housing. 7.Carefully withdraw gear lever from housing ensuring that spring loaded nylon pad is retained during removal. WARNING: Personal injury may result if nylon pad is not retained. Refit 8.Clean gear lever, housing and nylon pad. 9.Lubricate ball pin with multi-purpose grease and fit nylon pad and spring. 10.Depress nylon pad against spring pressure, position gear lever in housing with the nylon pad facing away from bias spring location. 11.Fit gear lever retaining bolt and special washer and tighten bolt to10 Nm (7 lbf.ft). 12.Using a suitable piece of tubing fitted over ends of bias spring, locate each end of bias spring to ball pins. 13.Fit upper gear lever to lower gear lever and tighten retaining nut to25 Nm (18 lbf.ft). 14.Adjust bias spring.See Adjustment. 15.Fit gear lever gaiter(s). 16.Fit gear lever knob.
37MANUAL GEARBOX 4 REPAIR MECHANISM AND HOUSING - GEAR SELECTOR Service repair no - 37.16.37 Remove 1.Remove gear lever knobs. 2.Remove gearbox tunnel carpet. 3.Remove gear lever gaiter(s) 4.Release and remove insulation pad from around gear levers. 5.Remove 2 screws securing relay/fuse panel and collect 2 spacers. 6.Release bulkhead carpet from LH side of tunnel and move aside. 7.Remove 13 screws securing tunnel cover. 8.Release and remove tunnel cover. 9.Remove 4 bolts securing gear change housing, remove housing, remove and discard gasket. 10.Using a suitable piece of tubing located over ends of bias spring, release both ends of bias spring from ball pins. 11.Loosen locknuts and remove bias spring adjusting screws. 12.Drift out roll pin, remove bias spring. 13.Remove nut and extension from lower gear lever.
MANUAL GEARBOX 5 REPAIR 14.Remove bolt and special washer securing lower gear lever in housing. 15.Carefully withdraw lower gear lever from the housing ensuring that the spring loaded nylon pad is retained during removal. WARNING: Personal injury may result if nylon pad is not retained. 16.Release nylon pad, recover spring. Refit 17.Clean components, gear change housing and mating face on remote housing. 18.Apply multi - purpose grease to ball pin and fit spring and nylon pad. 19.Depress nylon pad against spring pressure, position lower gear lever in housing with the nylon pad facing away from bias spring location. 20.Fit lower gear lever retaining bolt and special washer and tighten bolt to10 Nm (7 lbf.ft). 21.Fit upper gear lever to lower gear lever and tighten nut to25 Nm (18 lbf.ft). 22.Drift new roll pin into housing. 23.Fit bias spring adjusting screws and locknuts. 24.Using a suitable piece of tubing, locate both ends of bias spring over ball pins. 25.Fit new gasket to remote housing, position gear change housing to remote housing and tighten bolts to25 Nm (18 lbf.ft).26.Adjust bias springs.See Adjustment. 27.Fit and align tunnel cover, fit and tighten screws. 28.Secure bulkhead carpet to LH side of tunnel. 29.Position relay/fuse panel, fit spacers and tighten screws. 30.Fit insulation pad around gear levers. 31.Fit gear lever gaiter(s). 32.Fit gearbox tunnel carpet. 33.Fit gear lever knobs.