Range Rover Classic. Manual — part 61
33
CLUTCH
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 pump
9. 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
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