Land Rover Range Rover Classic Workshop 1995 Rover Manual

CLUTCH
5
REPAIR RENEWING HYDRAULIC DAMPER - Tdi
Service repair no - 33.15.05
NOTE: All flexible and pipe connections
and joints should be tightened to
15 Nm.
Remove
1.Remove the pipe between the slave cylinder and
damper.
2.Disconnect the hydraulic hose from the damper.
3.Remove the two bolts securing the damper to
the bracket and remove the damper.
Refit
4.Fit the damper to the bracket and tighten the two
bolts.
5.Connect the flexible hose to the damper.
6.Fit the pipe to the slave cylinder and to the...

CLUTCH
1
OVERHAUL MASTER CYLINDER
Service repair no - 30.20.07
1.Remove master cylinder.
See Repair, Master
Cylinder
Disassemble
2.Pull back and remove rubber sealing boot from
pushrod.
3.Depress push-rod and extract circlip.
4.Withdraw push-rod assembly.
5.Withdraw piston assembly.
6.Withdraw retainer and spring.
7.Remove two piston seals and piston washer.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid. Dry, using a lint-free cloth.
9.Examine cylinder bore and piston, ensure...

33CLUTCH
2
OVERHAUL SLAVE CYLINDER
Service repair no - 33.35.07
Overhaul
1.Remove slave cylinder.
See Repair, Slave
Cylinder
Disassemble
2.Withdraw rubber boot.
3.Withdraw push-rod.
4.Remove circlip.
5.Extract piston and seal assembly, applying low
pressure air to fluid inlet if necessary.
6.Withdraw spring.
7.Remove bleed valve.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid, and dry using lint-free cloth.
9.Examine cylinder bore and piston which must be
free from corrosion,...

CLUTCH
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Clutch pipes
Master cylinder union 15.................................................................................
Pipe joint 15....................................................................................................
Pipe to damper...

R380
1
DESCRIPTION AND OPERATION MANUAL TRANSMISSION
Description
The 77mm all synchromesh five speed manual
gearbox unit, is married to a Borg Warner two speed
chain drive transfer gearbox.
All the gears including reverse run on needle roller
bearings and the main, layshaft and primary shafts
are supported by tapered roller bearings.The whole of the geartrain is lubricated through
drillings in the shafts, supplied by a low pressure
pump driven from the rear of the layshaft. The gear
change has a single...

R380
1
FAULT DIAGNOSIS MANUAL GEARBOX
Symptom - Gear jumps out of engagement (any
forward gear)
1.Check condition and security of transmission
and engine mountings.
2.Check in situ, gear lever and selector
adjustments.
3.In situ, remove gearshift and check selector rail
yoke security.
Also check selector detent spring tension and
both spool retainers.
Suspect internal fault
See remove and overhaul manual.
4.Check action/operation of main selector rail and
forks.
5.Check condition of synchromesh and gear...

37MANUAL GEARBOX RANGE ROVER
2
FAULT DIAGNOSIS Symptom - Noise from gearbox in neutral, which
disappears when clutch is depressed.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.Drain lubricant and check for contamination or
metal particles.
Suspect worn bearings on layshaft, primary shaft
or front of main shaft. See remove and overhaul
manual.
Symptom - Noise from gearbox in one or more
gears when being driven.
1.Check lubricant specification and level, if low do
not...

R380
1
REPAIR R380 GEARBOX
Service repair no - 37.20.02
Remove
1.Site vehicle on ramp and chock wheels.
2.Disconnect battery negative lead.
3.Remove fan blade assembly.
NOTE: The nut securing viscous unit has
left hand thread.
4.Disconnect airflow meter to plenum chamber
hose. (V8i only)
5.Remove two gear lever knobs.
6.Remove floor mounted console assembly.See
CHASSIS AND BODY, Repair, Centre
Console
7.Remove padding from top of transmission
tunnel.
8.Loosen pinch bolt and remove upper gear lever....

37MANUAL GEARBOX RANGE ROVER
2
REPAIR 14.Mark each drive flange for reassembly and
disconnect front and rear propeller shafts from
transfer box. Tie the shafts to one side.
15.Disconnect multiplug from speed transducer.
16.Release breather pipe and electrical cables from
P clip on right hand side of gearbox.
17.Remove two bolts and withdraw clutch slave
cylinder from bell housing.
18.Remove transmission brake drum. Remove four
bolts securing back plate to transfer box, and tie
assembly aside complete...

R380
3
REPAIR Assembling transfer box to main gearbox
34.Stand gearbox bell housing face on two pieces
of wood.
35.Lower transfer gearbox onto main gearbox.
Secure with bolts and two nuts tighten to
40Nm
36.Refit breather pipe and selector link.
Transfer gearbox high/low link adjustment
37.Ensure transfer gearbox is in neutral position.
38.Set transfer gearbox lever in a vertical position.
Rotate fork end of rod until holes align with hole
in selector lever.
39.Fit clevis pin and retaining clip. Select...