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
damper and tighten the unions.
7.Bleed the hydraulic system. 
						

							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 they
are smooth to touch with no corrosion, score
marks or ridges. If in doubt, fit new components.
10.Fit new seals and rubber boot. These items are
all included in master cylinder overhaul kit.
11.Ensure that feed and by-pass ports are not
obstructed.
12.Ensure reservoir cap vent is clear.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt. Lubricate
cylinder bore and rubber seals with new
hydraulic fluid before assembly.
13.Fit a new piston washer and thinner of two piston
seals, lip last, over piston nose, up against
drilled piston head. Fit thicker seal into piston
groove with lip facing towards seal at opposite
end.
14.Insert spring and retainer into master cylinder
bore.
15.Insert piston and seal assembly, ensuring that
seal lips do not bend back.
16.Reverse 3 and 4, correctly locating circlip.
17.Stretch new rubber boot over push-rod, pack
with rubber grease. Fit securely into locating
groove.
18.Operate push-rod several times to ensure free
movement of internal components.
19.Fit master cylinder. 
						

							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, scores and ridges.
10.Replace seal and rubber boot using appropriate
repair kit.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt.
11.Fit bleed valve. Do not overtighten.
12.Lubricate seals, piston and bore using new
hydraulic fluid.
13.Fit seal into piston groove, lip of seal towards
fluid inlet end of cylinder.
14.Enter piston assembly, spring first, into cylinder
bore. Ensure that seal lip does not fold back.
15.Secure with circlip.
16.Fill rubber boot with rubber grease.
17.Reverse removal procedure. 1 to 3. 
						

							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 15...........................................................................................
Pipe out of damper 15.....................................................................................
Pipe to jump hose 15......................................................................................
Jump hose to pipe 15......................................................................................
Pipe to slave cylinder 15................................................................................. 
						

							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 rail selector and spool type
interlock. The main and transfer gearboxes ventilate
through nylon pipes, which terminate high up in the
engine compartment to prevent water entry when the
vehicle is operating in adverse conditions.
1. Mainshaft 1st gear
2. Mainshaft 2nd gear
3. Mainshaft 3rd gear
4. Primary input shaft
5. Mainshaft 5th gear
6. Layshaft
7. Mainshaft
8. Lubrication pump9. Drain plug
10. Ventilation pipe
11. Single rail gear shift
12. 1st/2nd synchromesh
13. Oil seals
14. 3rd/4th synchromesh
15. 5th gear synchromesh 
						

							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 dog
teeth.
6.Check main and layshaft end floats bearings and
adjustments.
7.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Reverse gear only jumps out of
engagment
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
reverse lever.
5.Check condition of reverse gear, angled
bearings and shaft.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.Symptom - Excessive force required to engage or
change gear, vehicle stationary or moving.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.In situ, lubricate gear mechanism, and check
selector adjustments.
3.In situ, remove gearshift and check selector rail
is free and that the yoke is secure. Also check
selector detent spring tension and both spool
retainers.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh unit or baulk rings
on affected gears. See remove and overhaul
manual.
Symptom - Noisy gear engagement, vehicle
stationary.
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults
Symptom - Noisy gear selection, vehicle moving.
1.Confirm that clutch operation is satisfactory.
2.Establish which gear/gears is causing noise.
3.Check lubricant specification and level, if low do
not top up at this stage.
4.Drain lubricant and check for contamination or
metal particles.
Suspect worn synchromesh. See remove and
overhaul manual.
5.Check condition of synchromesh unit, springs
and cones for distortion and wear. Also check
dog teeth for damage and cone mating surface
on gear for signs of overheating.
6.Check condition of all gearbox components,
ensure clearances and adjustments are correct
on reassembly.
Symptom - Noise from gearbox in neutral, which
changes tone or becomes worse when clutch is
depressed.
See CLUTCH, Fault diagnosis, Clutch
Noise - Mechanical Faults 
						

							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 top up at this stage.
2.Drain lubricant and check for contamination or
metal particles.
Suspect worn roller bearings on particular
mainshaft gears. See remove and overhaul
manual. 
						

							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.
9.Remove screws and detach high low lever and
main gear lever retaining plates.Underneath vehicle
10.Drain oil from transfer gearbox, main gearbox
and extension housing.
11.Refit plugs.
12.Disconnect heated oxygen sensor and remove
front section of exhausts. (V8i only)
13.Remove chassis cross member secured by eight
nuts and bolts. (V8i only) 
						

							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 with handbrake cable.
Remove transmission assembly
19.Position a suitable transmission hoist on rear
output housing to support weight of assembly.
20.Remove fixings and withdraw transfer gearbox
mountings.
21.Remove Chassis Cross member (Tdi only)
22.Remove front exhaust section. (Tdi only)
23.Fit adaptor plate to transmission hoist. Raise
hoist and position under transfer box.
See
TRANSFER GEARBOX, Service tools,
Adapter Plate Transfer Box
24.Secure fixture to transfer box mounting points.
25.Remove hoist from rear of transfer box.
26.Lower transmission until top of transfer gearbox
clears rear floor.
27.Position hoist under engine to support weight.
28.Remove bolts from bell housing.
29.Ensuring all fixings are released, withdraw
transmission.
Separating transfer box from gearbox
30.Remove transmission assembly from hoist and
cradle.
31.Place sling round transfer box and attach to
hoist.
32.Detach high low link from transfer gearbox
selector lever and remove breather pipe.
33.Remove bolts and two nuts retaining transfer
box to extension housing and separate. 
						

							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 high and
low transfer to ensure full engagement is
obtained. Repeat adjustment procedure if full
engagement is not evident.
Refit
40.Fit cradle to transmission hoist and transmission
to cradle. Apply Hylomar on bell housing mating
face with engine.
41.Select any gear in main and transfer gearbox to
facilitate entry of the input shaft. Ensure that the
clutch centre plate is in alignment.
42.Position and raise hoist to line up with engine,
feed handbrake cable through aperture in tunnel,
ensure that any pipes or electrical leads do not
become trapped.
43.Fit transmission assembly to engine and tighten
bolts to
40Nm
44.Reverse removal procedure noting following
points.
45.Tighten all fixings to the correct torque.
See
Specifications, torque, Torque Values
46.Fill both main and transfer gearboxes with
recommended oil up to level of filler hole. Apply
Hylomar sealant to threads and fit level plugs.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids