Range Rover. Manual — part 137
CLUTCH
3
REPAIR
Refit
16. Ensure mating faces are clean.
NOTE: New friction plates are supplied
with splines pre-greased.
17. If refitting existing friction plate, smear splines
with ’Molycote FB180’.
18. Position friction plate on flywheel. Fit
LRT-12-001 to align plate.
19. Position cover. Locate on dowels.
NOTE: If original cover is refitted, align
marks.
20. Secure cover with bolts. Tighten progressively,
in a diagonal sequence to
40 Nm (30 lbf.ft).
Remove LRT-12-001.
21. Position clutch housing onto dowels. Ensure
release fork engages with release bearing.
22. Secure clutch housing with bolts. Tighten to
40 Nm (30 lbf.ft)
23. Position flywheel access cover. Secure with
bolts.
24. Smear release lever push rod socket with
’Molycote FB180’.
25. Position slave cylinder on clutch housing.
Ensure pushrod is engaged with lever. Secure
cylinder with bolts. Tighten to
45 Nm (33 lbf.ft)
26. Secure push rod gaiter to clutch lever.
27. Fit gearbox assembly.
See MANUAL
GEARBOX, Repair.
33
CLUTCH
NEW RANGE ROVER
4
REPAIR
CLUTCH ASSEMBLY - DIESEL
Service repair no - 33.10.07
Remove
1. Remove gearbox assembly.
See MANUAL
GEARBOX, Repair.
2. Remove starter motor.
See ELECTRICAL,
Repair.
3. Release push rod gaiter from clutch lever.
4. Remove 2 bolts securing clutch slave cylinder.
Tie cylinder aside.
5. Release clutch fluid pipe from clips. Move pipe
bracket clear of clutch housing.
6. Remove 7 remaining bolts securing clutch
housing. Disengage release lever from release
bearing. Remove clutch housing.
NOTE: Spacer plate may become detached
from dowels but remain captive behind
flywheel.
7. If clutch cover is to be refitted, mark cover and
flywheel to aid re-assembly.
8. Fit LRT-12-106 to flywheel. Secure tool to
cylinder block with bolts.
CLUTCH
5
REPAIR
9. Working diagonally, sequentially slacken 6 bolts
securing clutch cover to flywheel. Remove bolts.
10. Remove cover assembly. Collect friction plate.
Check
11. Check linings of friction plate for excessive or
uneven wear, burning or contamination.
12. Check splines of friction plate for excessive
wear.
13. Check friction surface of cover for burning,
distortion or scoring.
14. Check fingers of cover for cracks and distortion.
15. Check release bearing for smooth operation.
16. Renew components as necessary.
CAUTION: Release bearing is packed with
grease, do not wash in solvent.
Refit
17. Ensure mating faces are clean.
NOTE: New friction plates are supplied
with splines pre-greased.
18. Smear friction plate splines with ’Molycote BR2’.
19. Position friction plate on flywheel. Fit
LRT-12-123 to align plate.
20. Position cover, locate on dowels.
NOTE: If original cover is refitted, align
marks.
21. Secure cover with bolts. Tighten progressively,
in a diagonal sequence, to:
M8 8.8 -
24 Nm (18 lbf.ft)
M8 10.9 -
34 Nm (25 lbf.ft)
22. Remove LRT-12-123 and LRT-12-106.
23. Position spacer plate onto dowels.
24. Position clutch housing onto dowels. Ensure
release fork engages with release bearing.
25. Align clutch fluid pipe bracket and coolant pipe
with clutch housing.
26. Secure clutch housing with bolts.
M8 - Tighten to
27 Nm (20 lbf .ft)
M10 - Tighten to
51 Nm (38 lbf.ft)
M12 - Tighten to
86 Nm (63 lbf.ft)
27. Smear push rod socket of release lever with
’Molycote FB180’.
28. Position slave cylinder on clutch housing.
Ensure push rod has engaged with lever. Secure
cylinder with bolts. Tighten to
45 Nm (33 lbf.ft)
29. Secure push rod gaiter to clutch lever.
30. Secure fluid pipe to clips.
31. Fit starter motor.
See ELECTRICAL, Repair.
32. Fit gearbox assembly.
See MANUAL
GEARBOX, Repair.
33
CLUTCH
NEW RANGE ROVER
6
REPAIR
MASTER CYLINDER
Service repair no - 33.20.01
Remove
1. Remove fascia closing panel.
See CHASSIS
AND BODY, Repair.
2. Remove 4 scrivets securing lower closing panel.
Disconnect multiplug from footwell lamp.
Remove panel.
3. Remove spring clip and clevis pin from master
cylinder push rod.
4. Position cloth beneath master cylinder to absorb
fluid spillage.
CAUTION: Do not allow brake fluid to
contact painted surfaces. Paint damage
will occur. If spilled, remove fluid. Wash
area with clean warm water.
5. Disconnect reservoir hose from master cylinder.
Plug hose and connection.
6. Disconnect pressure pipe from master cylinder.
Plug pipe and connection.
7. Remove 2 nuts securing master cylinder to
bulkhead. Remove master cylinder.
Refit
8. Ensure mating faces are clean.
9. Reverse removal procedure.
10. Bleed clutch system.
See this section.
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