Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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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 primary shaft (15) and takes up a neutral position between the flywheel (1) and the pressure plate (5), thus disconnecting the drive between the engine and the gearbox.
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 continue to run in contact with the flywheel or pressure plate. A number of faults can develop in the operation of the clutch for a variety of reasons and most faults are due to normal wear at high mileage. Problems can also occur if the unit has been renewed by an unskilled operator. Recognising and diagnosing a particular clutch fault is therefore of paramount importance in ensuring that the problem is rectified at the first attempt. Problems which develop in the clutch are as follows:- ·Clutch spin/drag ·Clutch slip ·Clutch judder/fierceCLUTCH SPIN - DRAG Symptoms Clutch spin is that, with engine running and clutch pedal depressed, the gears cannot be immediately engaged without making a grinding noise. This indicates the clutch is not making a clean break. However, if the clutch pedal is held depressed for several seconds the friction plate will eventually break free from the engine and the gear will engage silently. Clutch spin as it becomes more severe develops into clutch drag, making the silent engagement of a gear impossible, regardless of how long the pedal is held depressed. CLUTCH SLIP Symptoms Clutch slip is most evident climbing a hill or when the vehicle is moving off from stationary with a heavy load. As the clutch is released, slip occurs between the engine and the transmission, allowing the engine speed to increase without a corresponding increase in vehicle speed. Clutch slip can develop to the stage where no power is transmitted through the clutch as the pedal is released. CLUTCH JUDDER - FIERCE Symptoms Clutch judder or fierce engagement, like slip, is most likely to occur when the vehicle is moving off from stationary. As the clutch pedal is released the vehicle will move rapidly or in a series of jerks, which cannot be controlled even by careful operation of the clutch by the driver. It should be noted that a vehicle may display all the symptoms or any combination of the symptoms described, depending on the driving conditions vehicle load and operating temperatures.
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 relate to the clutch components shown in J6270 and J6271.See Description and operation, Description CLUTCH NOISE - MECHANICAL FAULTS Noise from clutch or gearbox in neutral, which disappears when clutch is depressed. Suspect gearbox input/primary shaft bearings See MANUAL GEARBOX, Fault diagnosis, R380 gearbox . Noise from clutch or gearbox in neutral, which changes tone or becomes worse when the clutch is depressed. Suspect worn release bearing. Knocking/rattling from clutch or gearbox in neutral, which is reduced or disappears when the clutch is depressed. Suspect worn/weak release lever retainer or clutch unit. Noise from clutch or gearbox in neutral, which disappears when clutch is depressed. Suspect gearbox fault See MANUAL GEARBOX, Fault diagnosis, R380 gearbox .HYDRAULIC FAULTS Unable to dis-engage clutch, little or no pedal resistance. 1.Check condition, specification and level of fluid. 2.Check pipes and cylinders for leaks. 3.Check that air vent in reservoir lid is clear. Suspect faulty master cylinder if no fluid leaks present See Repair, Master cylinder. Spongy pedal operation 1.Check condition, specification and level of fluid. 2.Check that air vent in reservoir lid is clear. Suspect air in fluid See Repair, Bleed hydraulic system . Clutch is difficult to dis-engage and/or does not immediately re-engage when pedal is released. 1.Check condition, specification and level of fluid. 2.Check that air vent in reservoir lid is clear. Suspect pedal pivot, master cylinder or slave cylinder seizure See Repair, Master cylinder.
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 locknuts.7.Check operation of clutch pedal and ensure that there is a minimum of 6 mm (0.25 in) of free play before pressure is felt. If necessary, readust master cylinder push-rod. 8.Fit pedal box gasket and top cover.
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, working evenly and diagonally. 4.Remove clutch assembly. 5.Withdraw clutch driven plate. Refit NOTE: To prevent driven plate sticking, lubricate splines using Rocol MV 3 or Rocol MTS 1000 grease. 6.Using centralising toolLRT-12-040to support clutch driven plate locate pressure plate on flywheel dowels. If fitting original pressure plate, align assembly marks. 7.Secure pressure plate cover fixings evenly, working in a diagonal sequence. Tighten to 34Nm (25 lbf/ft). 8.Fit gearbox to engineSee MANUAL GEARBOX, Repair, R380 Gearbox .BLEED HYDRAULIC SYSTEM Service repair no - 33.15.01 Procedure NOTE: During bleed procedure, keep fluid reservoir topped up to avoid introducing air to system. For hydraulic fluid recommendations See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended lubricants and fluids . 1.Attach suitable tubing to slave cylinder bleed screw. 2.Place free end of tube in a glass jar containing clutch fluid. 3.Loosen bleed screw. 4.Pump clutch pedal, pausing at end of each stroke, until fluid from tubing is free of air. NOTE: Keep free end of tube below surface of fluid. 5.Hold clutch pedal down, tighten bleed screw. 6.Top up fluid reservoir.
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 pedals. 5.Remove 6 bolts securing pedal bracket to bulkhead. 6.Remove screw securing speedometer cable retaining bracket to top of pedal bracket. 7.Move pipework and cables aside and lift out pedal bracket, complete with master cylinder, turn through 90°to ensure pedal clears aperture in bulkhead.8.Remove 6 screws and detach pedal box top cover and gasket. 9.Remove nut and washer securing master cylinder push rod to clutch pedal trunnion. 10.Remove 2 nuts and bolts and withdraw master cylinder from pedal bracket. Refit 11.Fit master cylinder to pedal bracket, engaging cylinder push rod through pedal trunnion. 12.Secure push rod to pedal trunnion. 13.Apply sealant to mating surfaces and fit pedal bracket to engine bulkhead. 14.Connect fluid pipe to master cylinder. 15.Bleed clutch hydraulic system See Bleed hydraulic system . 16.Check and adjust clutch pedal and master cylinder setting See Adjustment, Clutch pedal and master cylinder setting . 17.Fit top cover and gasket to pedal bracket. 18.On RH drive vehicles, refit air cleaner.
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). Refit 7.If removed, fit trunnion bush and trunnion to clutch pedal. Lubricate components with general purpose grease on assembly. 8.Fit pedal to bracket, insert pivot shaft and secure with new pin. 9.Fit pedal return spring. 10.Fit master cylinder and pedal bracket assembly See Master cylinder. 11.Adjust clutch pedal and master cylinder setting See Adjustment, Clutch pedal and master cylinder setting .
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 lbf/ft). 8.Prior to reassembly, grease pivot post, socket, slipper pads, pins, and ball end of slave cylinder push-rod. 9.Fit slipper pads onto release lever pins and locate lever on pivot post. 10.Smear release bearing sleeve inner diameter with molybdenum disulphide grease and fit to bearing guide, locating slipper pads to sleeve flats. 11.Fit new bearing sleeve retainer staple. 12.Fit clutch slave cylinder See Slave cylinder. 13.Fit gearbox See MANUAL GEARBOX, Repair, R380 Gearbox .SLAVE CYLINDER Service repair no - 33.35.01 NOTE: All hose and pipe connections and joints should be tightened to 15 Nm (11 lbf/ft). Remove 1.Drain hydraulic fluid from system at slave cylinder bleed valve. 2.Disconnect fluid pipe. 3.Remove 2 bolts and withdraw slave cylinder and backing plate. 4.If dust cover is not withdrawn with slave cylinder, withdraw it from bell housing. CAUTION: If removing slave cylinder with gearbox in situ, DO NOT detach push-rod and clip from clutch release lever in bell housing. Refit 5.Coat both sides of backing plate with Hylomar P232M waterproof jointing compound. 6.Locate backing plate and dust cover in position on slave cylinder. 7.Fit slave cylinder, engaging push-rod through centre of dust cover and with bleed screw uppermost. 8.Reconnect fluid pipe. 9.Replenish and bleed clutch hydraulic system See Bleed hydraulic system. 10.Check for fluid leaks with pedal depressed and also with system at rest.
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 retainer. 8.Withdraw spring and retainer. 9.Withdraw valve spacer and spring washer from valve stem. 10.Remove valve seal. Inspection 11.Clean all components in new hydraulic fluid and allow to dry. 12.Examine cylinder bore and piston, ensure that they are smooth to touch with no corrosion, score marks or ridges. If there is any doubt, fit new components. 13.The seals should be renewed with seals from master cylinder overhaul kit. Assemble 14.Smear seals with suitable rubber grease and remaining internal items with new hydraulic fluid. 15.Fit valve seal, flat side first, on end of valve stem. 16.Place bowed washer, domed side first, over small end of valve stem, see J6281. 17.Fit spacer to valve, legs first.
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 Service repair no - 33.35.07 Dismantle 1.Remove slave cylinder See Repair, Slave cylinder . 2.Withdraw dust cover. 3.Expel piston assembly, applying low pressure air to fluid inlet. 4.Withdraw spring. 5.Remove seal from piston. 6.Remove bleed valve. Inspection 7.Clean all components with new hydraulic fluid fluid and allow to dry. 8.Examine cylinder bore and piston, ensure that they are smooth to touch with no corrosion, score marks or ridges. If there is any doubt, fit new components. 9.Renew seal and dust cover from slave cylinder overhaul kit.