Land Rover Defender Workshop 1993 Rover Manual

OVERHAUL RELEASE BEARING ASSEMBLY 
OVERHAUL MASTER CYLINDER - All models 
1. Remove  the clutch  slave cylinder  from the bell Dismantle 
2. Withdraw  the  retaining staple, if fitted. 1. Remove the master  cylinder from the vehicle. 
3. Remove  the release  bearing assembly. 2. Remove  the circlip. 
4. Remove  spring clip  retaining  bolt and spring. 3. Withdraw the push-rod and  retaining  washer. 
5. Withdraw  the  release lever. 
6. Discard  worn parts. 
7. Smear  the pivot  with  grease  and fit the...

CLUTCH 
5. Prise the locking  prong of the spring  retainer Assemble 
clear of the piston  shoulder  and  withdraw  the 
piston. 
14. Smear  the seals  with  rubber  grease  and  the 
remaining  internal  items  with brake  and clutch 
stem  to align  with the  larger  hole in the spring 
15. Fit  the  valve  seal, flat side  first,  onto  the  end 
retainer  of the  valve  stem. 
16.  Place  the  spring  washer,  domed side first, 
over  the small  end 
of the valve  stem. 
17.  Fit the  spacer,  legs...

CLUTCH 
OVERHAUL SLAVE CYLlNDER 
Dismantle 
1 . Remove the  slave cylinder from the vehicle. 
3. Expel  the  piston  assembly, applying low 
4. Withdraw the spring. 
2. Withdraw the dust  cover. I 
pressure air  to the  fluid  inlet. 
5. Prise off the seal  from  the  piston. I 
23. Smear the  piston  with  rubber  grease and 
insert  the  assembly,  valve  end first,  into  the 
cylinder. 
24. Fit the  push-rod,  retaining  washer  and  circlip. 
Inspection 
6. Clean all components  with  cleaning...

CLUTCH 
CLUTCH PEDAL AND MASTER  CYLINDER  BLEED CLUTCH  HYDRAULIC  SYSTEM 
ADJUSTMENT 
When  the gearbox  and bell housing  assembly  has 
been  fitted 
to the vehicle  the hydraulic  clutch release 
system  must  be bled 
to expel  air, 
NOTE: During  the following  procedure,  keep the 
fluid  reservoir  topped
-up to avoid  introducing  air 
Adjust  into 
the system.  Use only  the fluid  recommended 
in  the  Lubrication  chart. Use only  new fluid  from 
2. Withdraw  the six screws  and remove  the...

CLUTCH 
RENEW  CLUTCH SLAVE CYLINDER  RENEW 
CLUTCH  MASTER  CYLINDER 
Left 
hand drive  vehicles 
To Remove 
1. Evacuate  clutch system  fluid at slave  cylinder  2. Remove  the bonnet. 
2. Disconnect  fluid pipe.  cylinder to the 
the  servo. 
3. Remove two securing  bolts and  withdraw 4. Carefully  ease  the  master cylinder  away from 
the  servo  without  imposing  any strain  upon 
the  brake fluid  pipes. 
4. If dust  cover is  not withdrawn  with slave 5. Disconnect  the  vacuum hose  from  the...

CLUTCH 
Refitting 
19. Fit the master cylinder  and steel  gasket to the 
pedal  box and insert  the  push
-rod through  the 
bush  and trunnion  and loosely  fit 
the single 
nut 
to the  end of the push-rod. 
20. Secure  the master  cylinder  with  the  two nuts 
and  bolts to  the pedal  box. 
21.  Fit the  pedal  box to the  bulkhead  resealing 
with  Bostic  adhesive  and  secure  with the six 
bolts. 
22.  Check  the clutch  pedal height  and  free
-play, 
adjust  if necessary.  Tighten the push...

LT77S MANUAL GEARBOX 
REMOVE LT77S  MANUAL  GEARBOX  AND LT230 11. Release the air filter hose at filter. 
TRANSFER BOX 12. Raise  the ramp. 
13. Remove  the eight  nuts and bolts  securing  the 
WARNING: Where the  use of a transmission  chassis  cross member and using a suitable 
hoist 
is necessary, it is absolutely  essential  to means of spreading  the  chassis,  remove the 
follow 
the manufacturers  instructions to ensure  cross member. 
safe  and effective  use of the  equipment.  14. Place  a...

LT77S MANUAL GEARBOX 
MATERIAL  AND WELDING  SPECIFICATION 
Steel Plate 
Tube 
BS 4848  (Part 2) 
BS 1449 (Grade 4  or 14) 
Arc  Welding BS 5135 
operating  rod. 
29.  Remove  the cleat  retaining  the  reverse  light 
40. Remove the breather  pipes. 
switch  wires from the 
RH side of the 
gearbox. 
30.  Disconnect  the  wire  from the reverse  light 
switch  situated  at the  top  rear 
of the  selector 
housing  and move  the  harness away from  the 
transmission. 
31.  Support  the engine  under  the...

LT77S MANUAL GEARBOX 
41. Hoist  the transfer  box into  position  ensuring 
that  the  loose  upper dowel  is fitted,  Assemble 
to 
the main  gearbox  extension  housing  and 
secure  with  the four  bolts  and 
two nuts. 
42.  Reverse  instructions 
37 to 40. 
59. Check  that  the  three drain plugs  are tight  and 
remove  the main  gearbox  and  transfer box 
filler  level  plugs.  Fill the  main  gearbox with a 
recommended 
oil until it begins  to run  out of 
the  filler  level hole.  Fit and...

DISMANTLE 
Bell housing 
1. Remove clutch release bearing. 
2. Remove  screw and spring  clip  and remove 
release lever. 
3. Remove  C clip  from  pivot post. 
4. Remove six bolts  and bell housing. 
EXTENSION  HOUSING 
1. Remove snap ring retaining  oil seal  collar. 
GEAR  SELECTOR  HOUSING 
1. Remove four bolts  and remove  main  gearbox 
selector  housing. 
2. Remove transfer  box housing. 
3.  Remove  remaining 
bolts and remove  remote 
housing. 
4. Drive  out quadrant  roll  pin. 
5. Move...