Discovery 2. Manual — part 532

CLUTCH - TD5

REPAIRS 33-1-13

REPAIRS

Clutch assembly

$% 33.10.01

Remove

1. Remove gearbox assembly.

+

MANUAL GEARBOX - R380,

REPAIRS, Gearbox - Diesel.

2. Restrain flywheel.

3. Working in diagonal sequence, progressively

loosen 6 nuts securing clutch cover to flywheel.

4. Remove clutch cover and clutch plate.
5. Renew all worn or damaged components.

Refit

1. Clean clutch cover and flywheel mating faces

and spigot bush in end of crankshaft.

2. Position clutch plate to flywheel with 'gearbox

side' facing towards gearbox.

3. Position tool LRT-12-152 through drive plate

into spigot bearing in crankshaft.

4. Fit clutch cover and locate on dowels.
5. Fit clutch cover nuts and progressively tighten

in diagonal sequence to 25 Nm (18 lbf.ft).

6. Fit gearbox assembly.

+

MANUAL GEARBOX - R380,

REPAIRS, Gearbox - Diesel.

CLUTCH - TD5

33-1-14 REPAIRS

Master cylinder

$% 33.20.01

CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.

Remove

1. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Release spring clip securing clutch pedal

clevis pin and remove pin from push rod and
clutch pedal.

3. Position container to catch spillage. Disconnect

hydraulic pipe from clutch master cylinder.

CAUTION: Always fit plugs to open
connections to prevent contamination.

4. Release clip and remove connecting hose from

clutch master cylinder.

5. Remove 2 bolts securing clutch master

cylinder to pedal box and remove clutch master
cylinder.

Refit

1. Clean master cylinder and pedal box mating

faces.

2. Position clutch master cylinder to pedal box, fit

bolts and tighten to 25 Nm (18 lbf.ft).

3. Position clevis pin to push-rod and clutch pedal

and secure with spring clip.

4. Fit connecting hose to brake master cylinder

and tighten clip.

5. Position hydraulic pipe and tighten union to 18

Nm (13 lbf.ft).

6. Bleed clutch.

+

CLUTCH - Td5, ADJUSTMENTS,

Clutch hydraulic system - bleed.

7. Remove stand(s) and lower vehicle.

CLUTCH - TD5

REPAIRS 33-1-15

Bearing and lever - clutch release

$% 33.25.12

Remove

1. Remove gearbox assembly.

+

MANUAL GEARBOX - R380,

REPAIRS, Gearbox - Diesel.

2. Remove retaining peg and remove release

bearing.

3. Remove bolt securing clutch release lever.

Remove retaining clip and clutch release lever.

Refit

1. Clean clutch release lever.
2. Examine clutch release lever pivot points for

wear.

3. Apply a smear of Molybdenum disulphide

grease to clutch release lever pivot points.

4. Fit retaining clip ensuring it locates over

release bearing pivot point washer, fit bolt and
tighten to 8 Nm (6 lbf.ft).

5. Clean release bearing and bearing sleeve

mating faces.

6. Apply a smear of Molybdenum disulphide

grease to release bearing sleeve.

7. Fit release bearing and secure with retaining

peg.

8. Fit gearbox assembly.

+

MANUAL GEARBOX - R380,

REPAIRS, Gearbox - Diesel.

Slave cylinder

$% 33.35.01

Remove

1. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Position container to catch spillage.

3. Disconnect hydraulic pipe from slave cylinder.

CAUTION: Always fit plugs to open
connections to prevent contamination.

4. Remove 2 bolts securing slave cylinder to

gearbox housing and collect heat shield.

5. Withdraw slave cylinder from gearbox housing

and push rod.

Refit

1. Clean ends of pipes, gearbox housing and

slave cylinder mating faces.

2. Lubricate end of push rod with Molybdenum

disulphide grease.

3. Locate slave cylinder to push rod and gearbox

housing.

4. Position heatshield. Fit bolts securing slave

cylinder and tighten to 25 Nm (18 lbf.ft).

5. Connect hydraulic pipe to slave cylinder.
6. Bleed clutch system.

+

CLUTCH - Td5, ADJUSTMENTS,

Clutch hydraulic system - bleed.

7. Remove stand(s) and lower vehicle.

CLUTCH - TD5

33-1-16 REPAIRS