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)

Рассказать друзьям