Defender (1999-2002). Manual — part 74
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CLUTCH
1
ADJUSTMENT
HYDRAULIC SYSTEM - BLEED
Service repair no - 33.15.01
Check
CAUTION: Ensure the fluid in the reservoir
is maintained between the minimum and
maximum levels throughout the bleed
procedure using new brake fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
1. Top up clutch system reservoir.
2. Raise front of vehicle and support on stands.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3. Remove dust cap, connect bleed tube to bleed
screw and submerge free end into a clear
container of brake fluid.
4. Loosen bleed screw, then apply steady pressure
to the clutch pedal, depressing it through its full
stroke. Allow the pedal to return unassisted.
5. Repeat the procedure until a flow of clean,
air-free fluid is purged into the container.
6. Hold pedal down and tighten bleed screw to 9
Nm (7 lbf.ft).
7. Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8. Remove stands and lower vehicle.
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CLUTCH
1
REPAIR
CLUTCH ASSEMBLY
Service repair no - 33.10.01.01
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX, Repair.
2. Restrain flywheel.
3. Working in sequence, loosen 6 nuts securing
clutch cover to flywheel.
4. Remove clutch cover and clutch plate.
Refit
5. Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
6. Position clutch drive plate to flywheel with
’gearbox side’ facing towards gearbox.
7. Position LRT-12-152 alignment tool through
drive plate into spigot bearing in crankshaft.
8. Fit clutch cover and locate on dowels.
9. Position clutch cover nuts and tighten in diagonal
sequence to 25 Nm (18 lbf.ft).
10. Fit gearbox assembly. See MANUAL
GEARBOX, Repair.
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33
CLUTCH
2
REPAIR
BEARING - CLUTCH RELEASE
Service repair no - 33.25.12
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX, Repair.
2. Remove retaining peg and remove release
bearing.
3. Remove bolt securing clutch release fork,
remove retaining clip and remove clutch release
fork.
Refit
4. Clean release fork.
5. Examine clutch release fork pivot points for
wear.
6. Apply a smear of Molybdenum disulphide grease
to release fork pivot points.
7. Fit retaining clip ensuring it locates over pivot
point washer.
8. Fit bolt and tighten to 10 Nm (7 lbf.ft).
9. Clean release bearing and bearing sleeve
mating faces.
10. Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
11. Fit release bearing and secure with retaining
peg.
12. Fit gearbox assembly. See MANUAL
GEARBOX, Repair.
CLUTCH - MASTER CYLINDER LH DRIVE
Service repair no - 33.20.01
Remove
1. Remove 3 screws securing closing panel to
lower ’A’ post.
2. Release closing panel sufficient to gain access
to clutch and brake pedal bracket bolts.
3. Remove clutch pedal rubber.
4. Remove 12 bolts securing clutch and brake
pedal brackets to body.
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