Defender 300Tdi (1996+). Manual — part 36
33
CLUTCH
2
REPAIR
MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All hose and pipe connections and
joints should be tightened to
15 Nm (11
lbf/ft).
Remove
1. Drain hydraulic fluid from system.
2. Disconnect fluid pipe at master cylinder. Plug
master cylinder fluid port and seal end of
hydraulic pipe to prevent ingress of dirt.
3. On RH drive vehicles, unclip air cleaner retaining
straps, disconnect bottom hose, and move
assembly aside.
4. From inside vehicle, remove fibre board closing
panel above pedals.
5. Remove 6 bolts securing pedal bracket to
bulkhead.
6. Remove screw securing speedometer cable
retaining bracket to top of pedal bracket.
7. Move pipework and cables aside and lift out
pedal bracket, complete with master cylinder,
turn through 90
°
to ensure pedal clears aperture
in bulkhead.
8. Remove 6 screws and detach pedal box top
cover and gasket.
9. Remove nut and washer securing master
cylinder push rod to clutch pedal trunnion.
10. Remove 2 nuts and bolts and withdraw master
cylinder from pedal bracket.
Refit
11. Fit master cylinder to pedal bracket, engaging
cylinder push rod through pedal trunnion.
12. Secure push rod to pedal trunnion.
13. Apply sealant to mating surfaces and fit pedal
bracket to engine bulkhead.
14. Connect fluid pipe to master cylinder.
15. Bleed clutch hydraulic system
See Bleed
hydraulic system .
16. Check and adjust clutch pedal and master
cylinder setting
See Adjustment, Clutch pedal
and master cylinder setting .
17. Fit top cover and gasket to pedal bracket.
18. On RH drive vehicles, refit air cleaner.
CLUTCH
3
REPAIR
CLUTCH PEDAL
Service repair no - 33.33.02
Remove
1. Remove pedal bracket assembly and master
cylinder
See Master cylinder .
2. Release return spring from clutch pedal.
3. Using a suitable punch, drift out securing pin and
withdraw pedal pivot shaft.
4. Withdraw clutch pedal, complete with trunnion
and bush.
5. If necessary remove pivot bushes.
6. Examine components for wear and damage,
renew as necessary.
NOTE: If new pedal pivot bushes are
required they must be reamed to 16 mm
(0.625 in).
Refit
7. If removed, fit trunnion bush and trunnion to
clutch pedal. Lubricate components with general
purpose grease on assembly.
8. Fit pedal to bracket, insert pivot shaft and secure
with new pin.
9. Fit pedal return spring.
10. Fit master cylinder and pedal bracket assembly
See Master cylinder .
11. Adjust clutch pedal and master cylinder setting
See Adjustment, Clutch pedal and master
cylinder setting .
33
CLUTCH
4
REPAIR
RELEASE BEARING ASSEMBLY
Service repair no - 33.10.07
Remove
1. Remove gearbox
See MANUAL GEARBOX,
Repair, R380 Gearbox .
2. Remove clutch slave cylinder
See Slave
cylinder .
3. Remove release bearing sleeve retainer staple.
4. Withdraw bearing and sleeve.
5. Remove clutch release lever from bearing guide,
complete with sliper pads.
6. If necessary, unscrew 2 bolts and remove
bearing guide from bell housing.
Refit
7. If removed, fit bearing guide to bell housing.
Tighten bolts to
25 Nm (18 lbf/ft).
8. Prior to reassembly, grease pivot post, socket,
slipper pads, pins, and ball end of slave cylinder
push-rod.
9. Fit slipper pads onto release lever pins and
locate lever on pivot post.
10. Smear release bearing sleeve inner diameter
with molybdenum disulphide grease and fit to
bearing guide, locating slipper pads to sleeve
flats.
11. Fit new bearing sleeve retainer staple.
12. Fit clutch slave cylinder
See Slave cylinder .
13. Fit gearbox
See MANUAL GEARBOX, Repair,
R380 Gearbox .
SLAVE CYLINDER
Service repair no - 33.35.01
NOTE: All hose and pipe connections and
joints should be tightened to
15 Nm (11
lbf/ft).
Remove
1. Drain hydraulic fluid from system at slave
cylinder bleed valve.
2. Disconnect fluid pipe.
3. Remove 2 bolts and withdraw slave cylinder and
backing plate.
4. If dust cover is not withdrawn with slave cylinder,
withdraw it from bell housing.
CAUTION: If removing slave cylinder with
gearbox in situ, DO NOT detach push-rod
and clip from clutch release lever in bell
housing.
Refit
5. Coat both sides of backing plate with Hylomar
P232M waterproof jointing compound.
6. Locate backing plate and dust cover in position
on slave cylinder.
7. Fit slave cylinder, engaging push-rod through
centre of dust cover and with bleed screw
uppermost.
8. Reconnect fluid pipe.
9. Replenish and bleed clutch hydraulic system
See Bleed hydraulic system .
10. Check for fluid leaks with pedal depressed and
also with system at rest.
CLUTCH
1
OVERHAUL
MASTER CYLINDER - OVERHAUL
Service repair no - 33.20.07
Dismantle
1. Remove master cylinder from vehicle
See
Repair, Master cylinder .
2. Remove circlip.
3. Withdraw push-rod and retaining washer.
4. Withdraw the piston assembly. If necessary,
apply a low air pressure to outlet port to expel
piston.
5. Prise locking prong of spring retainer clear of
piston shoulder and withdraw piston.
6. Withdraw piston seal.
7. Compress spring and position valve stem to
align with larger hole in spring retainer.
8. Withdraw spring and retainer.
9. Withdraw valve spacer and spring washer from
valve stem.
10. Remove valve seal.
Inspection
11. Clean all components in new hydraulic fluid and
allow to dry.
12. Examine cylinder bore and piston, ensure that
they are smooth to touch with no corrosion,
score marks or ridges. If there is any doubt, fit
new components.
13. The seals should be renewed with seals from
master cylinder overhaul kit.
Assemble
14. Smear seals with suitable rubber grease and
remaining internal items with new hydraulic fluid.
15. Fit valve seal, flat side first, on end of valve
stem.
16. Place bowed washer, domed side first, over
small end of valve stem, see J6281.
17. Fit spacer to valve, legs first.
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