Defender 90 / 110 / 130. Instruction - page 66
CLUTCH
.
...
,
OVERHAUL RELEASE BEARING ASSEMBLY
. . .
. .
,
I . Remove t h e clutch slave cylinder from the bell
2. Withdraw t h e retaining staple, if fitted.
3. Remove the release bearing assembly.
4. Remove spring clip retaining bolt and spring-
V8.
5 .
Remove the slipper pads
-
4-cylinder engines
6. Withdraw the
lever.
7.
Discard worn parts.
8. Smear the pivot
with
grease and
fit
the release
lever and retain with the spring clip and bolt
-
Smear the release bearing sleeve inner diameter
with
Molybdenum disulphide base grease.
housing.
only.
10. Fit the slipper pads.
11. Fit the release
assembly and retain with the
staple. The staple is to aid assembly and has no
other purpose. It may become dislodged in service,
.
without detriment.
,
.
Illustration
A .
V8 engine
Illustration
4-cylinder engines
3
,
12. Coat both sides of the backing plate with a
waterproof joint compound such as Hylomar
and locate the backing plate and dust cover
in position on
the
slave cylinder.
13. Check that the push-rod clip is in position.
14.
Fit the slave cylinder, engaging the push-rod
through the centre
of the dust cover and with the
bleed screw uppermost. Secure the cylinder with
the two bolts, tightening
to the correct
torque.
OVERHAUL MASTER CYLINDER
-
models
DISMANTLE
1. Remove the master cylinder from the vehicle.
2. Remove the circlip.
3. Withdraw the push-rod and retaining washer.
4. Withdraw the piston assembly.
If
neccssary, apply
a low air pressure to the
port to expel the
piston.
1
CLU
TC
H
5.
Prise the locking prong of the spring retainer clear
of
the piston shoulder and withdraw the piston.
6.
Withdraw t h e piston seal.
7.
Compress the spring and position the valve stem to
align with t h e larger hole in the spring retainer.
8.
Withdraw
spring and retainer.
9. Withdraw the valve spacer and spring washer from
the valve stem.
10. Remove the
seal.
Inspection
Assemble
14. Smear the
seals
with Castrol-Girling rubber grease
and
remaining internal items with Castrol-
Girling brake and clutch fluid.
15.
Fit the valve seal, flat side first, onto the end of the
valve stem.
16. Place the spring washer, domed side first, over the
small end of the valve stem.
17. Fit the spacer, legs first.
15
J
18. Place
t h e
coil spring over
the valve stem.
19.
the retainer into the spring.
20. Compress the spring and engage
valve stem in
the keyhole slot
in
the retainer.
11. Clean all components in Girling cleaning fluid and
allow to dry.
12.
Examine the cylinder bore and piston, ensure that
they are smooth to the touch with
no corrosion,
score marks
or ridges.
If
there is any doubt. fit new
21. Fit the seal, large diameter last, to the piston.
22. Insert the piston into the spring retainer and
replacements.
engage the locking prong.
The seals should
be
replaced
with
new
3
components.
continued
2
CLUTCH
OVERHAUL SLAVE CYLINDER
DISM
1. Remove the slave cylinder from the vehicle.
2. Withdraw the dust cover.
3. Expel the piston assembly, applying low pressure
4.
Withdraw the spring.
5 .
Prise off the seal from the piston.
air to the fluid inlet.
23. Smear t h e piston with Castrol-Girling rubber
grease and insert the assembly, valve end first, into
the cylinder.
24. Fit the push-rod, retaining washer and circlip.
BLEED CLUTCH HYDRAULIC SYSTEM
When the gearbox and
housing assembly has been
fitted to the vehicle the hydraulic clutch release system
must be bled to expel air.
NOTE: During the following procedure, keep the fluid
reservoir topped-up to avoid introducing air into the
system. Use only the fluid recommended in the
Lubrication chart. Use only new fluid from
a sealed
Inspection
6. Clean
all
components with Girling cleaning fluid
and allow to dry.
7.
Examine the cylinder bore and piston, ensure that
t h e y
are smooth
to the touch with no corrosion,
score marks or ridges. If there is any doubt,
fit
replacement.
8.
The seal should be replaced with
a new
pon
n
.
Assemble
9. Smear the seal with Castrol-Girling rubber grease
and the remaining internal items with Castrol-
Girling brake and clutch fluid.
10. Fit the seal,
diameter last, to the piston.
11.
Locate the conical spring, small diameter first,
the front end of the piston.
12.
Smear the piston, with Castrol-Girling rubber
grease and insert
the
assembly, spring end first,
,
container.
into the cylinder.
13.
Fill
the
with
Castrol-Girling rubber
cylinder bleed screw and immerse the free end of the
grease and fit the cover to the cylinder.
tube
in a
glass jar containing new clutch fluid.
2 . Slacken the bleed screw and depress the clutch
pedal, pausing at the end
of
each stroke, until the
fluid issuing from the tubing is free of air
with
the
tube free end below the surface
of
t h e
fluid
in
the
container. Whilst holding the clutch pedal down and
with the free end
of the tube below the fluid, tighten
the bleed screw.
.
.
3
CLUTCH
PEDAL AND MASTER CYLINDER
ADJUSTMENT
The correct height for the clutch
from the
floor of the footwell, without a mat, to the lower
edge
of the pedal is
140
(5.5
in), dimension
'A'.
Adjust
2. Withdraw the six screws and remove the top plate.
3 . Slacken master cylinder push-rod locknuts
to
provide free movement
of the push-rod through
the pedal trunnion.
4. Slacken the adjustment screw locknut.
5.
To increase the pedal height, turn the adjustment
screw anti-clockwise. T o reduce turn clockwise.
When correct tighten the locknut.
6. To adjust the master cylinder push-rod, check that
push-rod
has free-play through
trunnion.
7.
Adjust the locknuts until the push-rod has
(0.062
in)
free-play between the push-rod and
master cylinder. When correct tighten the
knu ts
.
8.
Check that there is
6
(0.350 in) free movement
of the pedal at the pad.
If necessary
the
push-rod.
9. Refit the top plate.
IN
ENGLAND
BY
COVENTRY
PRINTERS
37210)