Land Rover Defender Workshop Rover Manual

33CLUTCH
2 FAULT
DIAGNOSIS
FAULT/SYMPTOM
CHART
Symptoms
Slip Spin/Drag Judder/Fierce FaultItem
* ** Wornoroil on clutch linings 2
* ** Mechanicaldamage 45678
* * Distortedclutchplate 2
* Failedorair inhydraulic system 1213
* *Primaryshafttightfitincrankshaft bush 1517
* Clutchsplines sticking 215
* Weakclutch platesprings orinsecure/worn
engine/gearbox mountings 6
* Insecure/wornpropellershafts
* Insecure/wornsuspensioncomponents/rubber
bushes
The items refered tointhis chart relate tothe clutch...

CLUTCH1
ADJUSTMENT
CLUTCH
PEDALANDMASTER CYLINDER
SETTING
1. Remove 6screws anddetach pedalboxtop
cover andgasket.
2. Slacken bothlocknuts onmaster cylinder
push-rod.
3. Check distance fromlower edgeofclutch pedal
to floor. Correct measurement is140 mm(5.50
in) without floormat.
4.Adjust pedalstopasnecessary toobtain correct
setting.
5. Adjust master cylinder pushrodtoobtain
approximately 1,5mm (1/16 in)free play
between push-rod andmaster cylinder piston.
6. Tighten push-rod locknuts. 7.
Check operation...

CLUTCH1
REPAIR
CLUTCH
ASSEMBLY
Service repairno-33.10.01
Clutch pressure plate
Renew pressure plateifdiaphragm springfingers are
worn orifpressure plateshows signsofwear, cracks
or burning.
Clutch drivenplate
Renew drivenplateifcentre hubsplines areworn orif
lining iscontaminated, burnedorunevenly worn.
Remove 1. Remove gearbox
SeeMANUAL GEARBOX,
Repair, R380Gearbox
.
2. Mark position ofclutch pressure platetoflywheel
for reassembly.
3.Remove pressure platesecuring bolts,working
evenly anddiagonally.
4....

33CLUTCH
2 REPAIR
MASTER
CYLINDER
Service repairno-33.20.01/03
NOTE: Allhose andpipe connections and
joints should betightened to
15Nm (11
lbf/ft).
Remove
1. Drain hydraulic fluidfrom system.
2. Disconnect fluidpipe atmaster cylinder. Plug
master cylinder fluidportandseal endof
hydraulic pipetoprevent ingressofdirt.
3. On RH drive vehicles, unclipaircleaner retaining
straps, disconnect bottomhose,andmove
assembly aside.
4. From inside vehicle, removefibreboard closing
panel above pedals.
5.Remove 6bolts...

CLUTCH3
REPAIR
CLUTCH
PEDAL
Service repairno-33.33.02
Remove 1. Remove pedalbracket assembly andmaster
cylinder
See Master cylinder.
2. Release returnspring fromclutch pedal.
3.Using asuitable punch,driftoutsecuring pinand
withdraw pedalpivotshaft.
4. Withdraw clutchpedal, complete withtrunnion
and bush.
5. Ifnecessary removepivotbushes.
6. Examine components forwear anddamage,
renew asnecessary.
NOTE: Ifnew pedal pivotbushes are
required theymust bereamed to16 mm
(0.625 in).
Refit 7. Ifremoved,...

33CLUTCH
4 REPAIR
RELEASE
BEARINGASSEMBLY
Service repairno-33.10.07
Remove 1. Remove gearbox
SeeMANUAL GEARBOX,
Repair, R380Gearbox
.
2. Remove clutchslavecylinder
SeeSlave
cylinder
.
3. Remove releasebearing sleeveretainer staple.
4. Withdraw bearingandsleeve.
5. Remove clutchrelease leverfrombearing guide,
complete withsliper pads.
6. Ifnecessary, unscrew2bolts andremove
bearing guidefrombellhousing.
Refit 7. Ifremoved, fitbearing guidetobell housing.
Tighten boltsto
25Nm (18lbf/ft).
8.Prior...

CLUTCH1
OVERHAUL
MASTER
CYLINDER -OVERHAUL
Service repairno-33.20.07
Dismantle 1. Remove mastercylinder fromvehicle
See
Repair, Mastercylinder
.
2.Remove circlip.
3. Withdraw push-rodandretaining washer.
4. Withdraw thepiston assembly. Ifnecessary,
apply alow airpressure tooutlet porttoexpel
piston.
5. Prise locking prongofspring retainer clearof
piston shoulder andwithdraw piston.
6. Withdraw pistonseal.
7. Compress springandposition valvestemto
align withlarger holeinspring retainer.
8.Withdraw...

33CLUTCH
2 OVERHAUL
18.
Place coilspring overvalve stem.
19. Insert retainer intospring.
20. Compress springandengage valvestemin
keyhole slotinretainer.
21. Fitseal, large diameter last,topiston.
22. Insert piston intospring retainer andengage
locking prong.
23. Smear pistonwithsuitable rubbergrease and
insert assembly, valveendfirst, intocylinder.
24. Fitpush-rod, retainingwasherandcirclip.
25. Fitclutch master cylinder tovehicle
See Repair,
Master cylinder
. SLAVE
CYLINDER -OVERHAUL
Service...

CLUTCH3
OVERHAUL
Assemble
10. Fitbleed valvetocylinder body,donot
overtighten.
11. Lubricate seals,piston andbore withnew
hydraulic fluid.
12. Fitseal intopiston groove withlipofseal
towards fluidinletendofcylinder.
13. Locate springoverfront endofpiston.
14. Fitassembly, springfirst,intocylinder ensuring
seal lipdoes notfold back.
15. Filldust cover withsuitable rubbergrease andfit
cover tocylinder.
16. Fitslave cylinder
SeeRepair, Slavecylinder.  

MANUALGEARBOX
1
DESCRIPTION
ANDOPERATION
R380
GEARBOX
Description The allsynchromesh fivespeed manual gearbox unit,
is married toatwo speed transfer gearbox.
All the gears, including reverse,runonneedle roller
bearings andthemain, layshaft andprimary shafts
are supported bytapered rollerbearings. The
whole ofthe geartrain islubricated through
drillings inthe shafts, supplied byalow pressure
pump driven fromtherear ofthe layshaft. Thegear
change hasasingle railselector andspool type
interlock. Themain...