Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual

33CLUTCH
2
DESCRIPTION AND OPERATION
When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever (10), bearing (9), to the inner fingers of the
diaphragm spring (4).
The diaphragm spring (4) pivots on the bearing rings
(7) and fulcrum posts (6) causing the pressure plate
(5) to release the clamping force on the friction plate
and linings (2).As the the clamping force is removed from the friction
plate (2), the plate slides on the splines of the...

CLUTCH
1
FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS
For the clutch to operate correctly it is important the
following conditions are satisfied:-
·The primary shaft (15) must be free in the
crankshaft spigot bush (17).
·The friction plate (2) must be able to slide easily on
the splines on the primary shaft (15), to a position
where it does not contact either the flywheel or the
pressure plate.
·The friction plate must not be distorted or the
linings contaminated with oil, which may cause it to
stick or...

33CLUTCH
2
FAULT DIAGNOSIS FAULT/SYMPTOM CHART
Symptoms
Slip Spin/Drag Judder/Fierce Fault Item
* * * Worn or oil on clutch linings 2
* * * Mechanical damage45678
* * Distorted clutch plate 2
* Failed or air in hydraulic system 12 13
* * Primary shaft tight fit in crankshaft bush 15 17
* Clutch splines sticking 2 15
* Weak clutch plate springs or insecure/worn
engine/gearbox mountings6
* Insecure/worn propeller shafts
* Insecure/worn suspension components/rubber
bushes
The items refered to in this chart...

CLUTCH
1
ADJUSTMENT CLUTCH PEDAL AND MASTER CYLINDER
SETTING
1.Remove 6 screws and detach pedal box top
cover and gasket.
2.Slacken both locknuts on master cylinder
push-rod.
3.Check distance from lower edge of clutch pedal
to floor. Correct measurement is 140 mm (5.50
in) without floor mat.
4.Adjust pedal stop as necessary to obtain correct
setting.
5.Adjust master cylinder push rod to obtain
approximately 1,5 mm (1/16 in) free play
between push-rod and master cylinder piston.
6.Tighten push-rod...

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Remove
1.Remove gearbox
See MANUAL GEARBOX,
Repair, R380 Gearbox
.
2.Mark position of clutch pressure plate to flywheel
for reassembly.
3.Remove pressure plate securing bolts,...

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...

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)....

33CLUTCH
4
REPAIR RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1.Remove gearbox
See MANUAL GEARBOX,
Repair, R380 Gearbox
.
2.Remove clutch slave cylinder
See Slave
cylinder
.
3.Remove release bearing sleeve retainer staple.
4.Withdraw bearing and sleeve.
5.Remove clutch release lever from bearing guide,
complete with sliper pads.
6.If necessary, unscrew 2 bolts and remove
bearing guide from bell housing.
Refit
7.If removed, fit bearing guide to bell housing.
Tighten bolts to
25 Nm (18...

CLUTCH
1
OVERHAUL MASTER CYLINDER - OVERHAUL
Service repair no - 33.20.07
Dismantle
1.Remove master cylinder from vehicle
See
Repair, Master cylinder
.
2.Remove circlip.
3.Withdraw push-rod and retaining washer.
4.Withdraw the piston assembly. If necessary,
apply a low air pressure to outlet port to expel
piston.
5.Prise locking prong of spring retainer clear of
piston shoulder and withdraw piston.
6.Withdraw piston seal.
7.Compress spring and position valve stem to
align with larger hole in spring...

33CLUTCH
2
OVERHAUL
18.Place coil spring over valve stem.
19.Insert retainer into spring.
20.Compress spring and engage valve stem in
keyhole slot in retainer.
21.Fit seal, large diameter last, to piston.
22.Insert piston into spring retainer and engage
locking prong.
23.Smear piston with suitable rubber grease and
insert assembly, valve end first, into cylinder.
24.Fit push-rod, retaining washer and circlip.
25.Fit clutch master cylinder to vehicle
See Repair,
Master cylinder
.SLAVE CYLINDER - OVERHAUL...