Land Rover Defender Workshop Rover Manual
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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 components showninJ6270 andJ6271. See Description and operation, Description CLUTCHNOISE-MECHANICAL FAULTS Noise fromclutch orgearbox inneutral, which disappears whenclutch isdepressed. Suspect gearboxinput/primary shaftbearings SeeMANUAL GEARBOX, Faultdiagnosis, R380 gearbox . Noise fromclutch orgearbox inneutral, which changes toneorbecomes worsewhentheclutch is depressed. Suspect wornrelease bearing. Knocking/rattling fromclutch orgearbox in neutral, whichisreduced ordisappears whenthe clutch isdepressed. Suspect worn/weak releaseleverretainer or clutch unit. Noise fromclutch orgearbox inneutral, which disappears whenclutch isdepressed. Suspect gearboxfault SeeMANUAL GEARBOX, Faultdiagnosis, R380gearbox . HYDRAULIC FAULTS Unable todis-engage clutch,littleorno pedal resistance. 1. Check condition, specification andlevel offluid. 2. Check pipesandcylinders forleaks. 3. Check thatairvent inreservoir lidisclear. Suspect faultymaster cylinder ifno fluid leaks present See Repair, Mastercylinder. Spongy pedaloperation 1. Check condition, specification andlevel offluid. 2. Check thatairvent inreservoir lidisclear. Suspect airinfluid See Repair, Bleed hydraulic system . Clutch isdifficult todis-engage and/ordoesnot immediately re-engagewhenpedal isreleased. 1. Check condition, specification andlevel offluid. 2. Check thatairvent inreservoir lidisclear. Suspect pedalpivot,master cylinder orslave cylinder seizure SeeRepair, Mastercylinder.
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 ofclutch pedalandensure that there isaminimum of6m m (0.25 in)offree play before pressure isfelt. Ifnecessary, readust master cylinder push-rod. 8. Fitpedal boxgasket andtopcover.
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. Remove clutchassembly. 5. Withdraw clutchdriven plate. Refit NOTE: Toprevent drivenplatesticking, lubricate splinesusingRocol MV3or Rocol MTS1000 grease. 6. Using centralising toolLRT-12-040 tosupport clutch driven platelocate pressure plateon flywheel dowels.Iffitting original pressure plate, align assembly marks. 7. Secure pressure platecover fixings evenly, working inadiagonal sequence. Tightento 34Nm(25lbf/ft). 8.Fitgearbox toengineSee MANUAL GEARBOX, Repair,R380Gearbox . BLEED HYDRAULIC SYSTEM Service repairno-33.15.01 Procedure NOTE: During bleedprocedure, keepfluid reservoir toppeduptoavoid introducing air tosystem. Forhydraulic fluid recommendations See LUBRICANTS, FLUIDS AND CAPACITIES, Information,Recommended lubricants andfluids . 1. Attach suitable tubingtoslave cylinder bleed screw. 2. Place freeendoftube inaglass jarcontaining clutch fluid. 3. Loosen bleedscrew. 4. Pump clutchpedal, pausing atend ofeach stroke, untilfluidfrom tubing isfree ofair. NOTE: Keepfreeendoftube below surface offluid. 5. Hold clutch pedaldown, tighten bleedscrew. 6. Top upfluid reservoir.
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 securing pedalbracket to bulkhead. 6. Remove screwsecuring speedometer cable retaining brackettotop ofpedal bracket. 7. Move pipework andcables asideandliftout pedal bracket, complete withmaster cylinder, turn through 90°to ensure pedalclears aperture in bulkhead. 8. Remove 6screws anddetach pedalboxtop cover andgasket. 9. Remove nutand washer securing master cylinder pushrodtoclutch pedaltrunnion. 10. Remove 2nuts andbolts andwithdraw master cylinder frompedal bracket. Refit 11. Fitmaster cylinder topedal bracket, engaging cylinder pushrodthrough pedaltrunnion. 12. Secure pushrodtopedal trunnion. 13. Apply sealant tomating surfaces andfitpedal bracket toengine bulkhead. 14. Connect fluidpipe tomaster cylinder. 15. Bleed clutch hydraulic system SeeBleed hydraulic system . 16. Check andadjust clutchpedalandmaster cylinder setting SeeAdjustment, Clutchpedal and master cylinder setting . 17. Fittop cover andgasket topedal bracket. 18. OnRH drive vehicles, refitaircleaner.
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, fittrunnion bushandtrunnion to clutch pedal. Lubricate components withgeneral purpose greaseonassembly. 8. Fitpedal tobracket, insertpivotshaft andsecure with new pin. 9. Fitpedal return spring. 10. Fitmaster cylinder andpedal bracket assembly SeeMaster cylinder. 11. Adjust clutchpedalandmaster cylinder setting SeeAdjustment, Clutchpedalandmaster cylinder setting .
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 toreassembly, greasepivotpost, socket, slipper pads,pins,andballend ofslave cylinder push-rod. 9. Fitslipper padsontorelease leverpinsand locate leveronpivot post. 10. Smear release bearing sleeveinnerdiameter with molybdenum disulphidegreaseandfitto bearing guide,locating slipperpadstosleeve flats. 11. Fitnew bearing sleeveretainer staple. 12. Fitclutch slavecylinder SeeSlave cylinder. 13. Fitgearbox See MANUAL GEARBOX, Repair, R380 Gearbox . SLAVE CYLINDER Service repairno-33.35.01 NOTE: Allhose andpipe connections and joints should betightened to 15Nm (11 lbf/ft). Remove 1. Drain hydraulic fluidfrom system atslave cylinder bleedvalve. 2. Disconnect fluidpipe. 3.Remove 2bolts andwithdraw slavecylinder and backing plate. 4. Ifdust cover isnot withdrawn withslave cylinder, withdraw itfrom bellhousing. CAUTION: Ifremoving slavecylinder with gearbox insitu, DONOT detach push-rod and clipfrom clutch release leverinbell housing. Refit 5. Coat bothsides ofbacking platewithHylomar P232M waterproof jointingcompound. 6. Locate backing plateanddust cover inposition on slave cylinder. 7. Fitslave cylinder, engaging push-rodthrough centre ofdust cover andwith bleed screw uppermost. 8. Reconnect fluidpipe. 9. Replenish andbleed clutch hydraulic system SeeBleed hydraulic system. 10. Check forfluid leaks withpedal depressed and also withsystem atrest.
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 springandretainer. 9. Withdraw valvespacer andspring washer from valve stem. 10. Remove valveseal. Inspection 11. Clean allcomponents innew hydraulic fluidand allow todry. 12. Examine cylinderboreandpiston, ensure that they aresmooth totouch withnocorrosion, score marks orridges. Ifthere isany doubt, fit new components. 13. The seals should berenewed withseals from master cylinder overhaul kit. Assemble 14. Smear sealswithsuitable rubbergrease and remaining internalitemswithnew hydraulic fluid. 15. Fitvalve seal,flatside first, onend ofvalve stem. 16. Place bowed washer, domedsidefirst, over small endofvalve stem, seeJ6281. 17. Fitspacer tovalve, legsfirst.
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 repairno-33.35.07 Dismantle 1. Remove slavecylinder SeeRepair, Slave cylinder . 2. Withdraw dustcover. 3. Expel piston assembly, applyinglowpressure air to fluid inlet. 4. Withdraw spring. 5. Remove sealfrom piston. 6. Remove bleedvalve. Inspection 7. Clean allcomponents withnew hydraulic fluid fluid andallow todry. 8. Examine cylinderboreandpiston, ensure that they aresmooth totouch withnocorrosion, score marks orridges. Ifthere isany doubt, fit new components. 9. Renew sealanddust cover fromslave cylinder overhaul kit.
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 andtransfer gearboxes ventilate through nylonpipes, whichterminate highupinthe engine compartment toprevent waterentrywhen the vehicle isoperating inadverse conditions. R380Gearbox Components 1. Mainshaft 1stgear 2. Mainshaft 2ndgear 3. Mainshaft 3rdgear 4. Primary inputshaft/4th gear 5. Mainshaft 5thgear 6. Layshaft 7. Mainshaft 8. Lubrication pump 9. Oil filter 10. Ventilation pipe 11. Single railgear shift 12. 1st/2nd synchromesh 13. Oilseals 14. 3rd/4th synchromesh 15. 5th/reverse gearsynchromesh 16. Selective spacers(mainshaft/layshaft endfloat) 17. Selective spacer(5thgear/reverse hub)