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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

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    							33CLUTCH
    8
    DESCRIPTION AND OPERATION The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
    ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring
    gear is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear.
    The holes are positioned at 10°intervals with four 20°spaces. The holes are used by the crankshaft position
    sensor for engine management.
    The dual mass flywheel is used to insulate the gearbox from torsional and transient vibrations produced by the
    engine. The flywheel comprises primary and secondary flywheels with the drive between the two transferred by a
    torsional damper which comprises four coil springs. The springs are located in the inside diameter of the primary
    flywheel. Two of the springs are of smaller diameter and fit inside the larger diameter springs.
    The primary flywheel locates the ring gear and is attached to the crankshaft flange with eight bolts. The two pairs
    of coil springs are located in a recess in the flywheel between two riveted retainers. A roller bearing is pressed
    onto the central boss of the primary flywheel and retained with a riveted plate. The bearing provides the mounting
    for the secondary flywheel.
    The secondary flywheel comprises two parts; an outer flywheel which provides the friction surface for the clutch
    drive plate and an inner drive plate which transfers the drive from the primary flywheel, via the coil springs, to the
    outer flywheel. The two components of the secondary flywheel are secured to each other with rivets. The inner
    drive plate is located between the two pairs of coil springs and can rotate on the ball bearing in either direction
    against the combined compression force of the four coil springs. Under high torque loading conditions the
    secondary flywheel can rotate in either direction up to 70°in relation to the primary flywheel.
    The operating face of the secondary flywheel is machined to provide a smooth surface for the drive plate to
    engage on. Three dowels and six studs and nuts provide for the location and attachment of the pressure plate. 
    						
    							CLUTCH
    9
    DESCRIPTION AND OPERATION Pressure plate
    1.Leaf spring
    2.Drive plate
    3.Pressure plate4.Cover
    5.Diaphragm
    6.Rivet 
    						
    							33CLUTCH
    10
    DESCRIPTION AND OPERATION The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates
    with the dual mass flywheel.
    The pressure plate is forged from cast iron and machined to provide a smooth surface for the drive plate to
    engage on. Three lugs on the outer diameter of the pressure plate connect it via three leaf spring to the cover. The
    leaf springs have three tempered steel leaves which assist in pulling the pressure plate away from the drive plate
    when the clutch pedal is depressed.
    The cover is made from pressed steel and houses all pressure plate components. Shouldered rivets support the
    diaphragm inside the cover. The rivets heads are chamfered to allow the diaphragm to pivot when pressure is
    applied to it by the release bearing. Three holes in the cover locate on the dowels on the flywheel and six further
    holes provide for the attachment of the cover to the flywheel with six nuts. Larger holes in the cover provide
    ventilation for the drive plate and pressure plate and flywheel contact surfaces.
    The diaphragm comprises a cast ring with eighteen fingers. The diaphragm is attached to the cover with nine
    shouldered rivets. The inner head of each rivet is chamfered to allow the diaphragm to pivot when the clutch is
    depressed or released. When pressure is applied to the fingers of the diaphragm by the release bearing, the
    diaphragm pivots on the rivets and moves away from the pressure plate, releasing the force applied to the
    pressure plate and allowing the drive plate to slip between the pressure plate and the flywheel. 
    						
    							CLUTCH
    11
    DESCRIPTION AND OPERATION Drive plate
    1.Friction material
    2.Inner plate3.Hub
    4.Spring steel plate
    The drive plate is of the rigid centre type and is sandwiched between the flywheel and the pressure plate. The
    drive plate has a splined hub which engages with the splines on the primary drive shaft from the gearbox. The hub
    is attached to an inner plate which is pressed onto the hub. A spring steel plate is riveted to the inner plate with
    eight rivets and provides the attachment surface for the drive plate friction material. The spring steel plate allows
    some axial compliance and contributes to smooth clutch operation. The friction material comprises two 267 mm
    (10.5 in.) discs which are secured with rivets to each side of the spring steel plate. The rivets are installed through
    recessed holes in the disc and emerge in recessed holes in the opposite disc. 
    						
    							33CLUTCH
    12
    DESCRIPTION AND OPERATION OPERATION
    Hydraulic operation
    When the clutch pedal is depressed, the master cylinder piston is pushed into the master cylinder. The movement
    of the piston pressurises the fluid in the master cylinder, forcing the pressurised fluid into the hydraulic feed pipe to
    the slave cylinder. The hydraulic pressure is felt at the slave cylinder piston which moves under the hydraulic force
    applied, pushing the clutch release lever via the piston rod.
    When the clutch pedal is released, the force applied to the release lever by the fingers of the diaphragm, moves
    the release lever, which pushes the slave cylinder piston into the cylinder. The displaced hydraulic fluid is pushed
    up the hydraulic feed pipe and returns to the master cylinder.
    Mechanism operation
    When the clutch pedal is depressed, hydraulic pressure extends the piston and rod in the slave cylinder. The
    extension of the piston pushes the rod against the outer end of the release lever which pivots around the ball
    spigot.
    The inner end of the release lever pivots towards the engine applying pressure to the release bearing. The release
    bearing slides along the release bearing sleeve and pushes on the fingers of the diaphragm. The diaphragm
    pivots around the chamfered rivets in the cover. As the diaphragm is deflected, it removes pressure from the
    pressure plate. The pressure plate moves away from the drive plate assisted by the three leaf springs.
    The removal of force from the pressure plate on the drive plate reduces the friction between the dual mass
    flywheel, drive plate and pressure plate. The drive plate slips between the flywheel and the pressure plate
    preventing rotary movement being transferred from the flywheel and pressure plate to the primary driveshaft.
    When the clutch pedal is released, hydraulic force is removed from the piston in the slave cylinder. This allows the
    fingers of the diaphragm to push the release bearing along the release bearing sleeve. The movement of the
    release bearing moves the release lever which pivots on the ball spigot, pushing the piston and rod back into the
    slave cylinder.
    The removal of pressure from the release bearing on the diaphragm, causes the diaphragm to pivot around the
    chamfered rivets in the cover. The force applied to the pressure plate from the diaphragm overcomes the force of
    the leaf springs and the pressure plate moves towards the drive plate and flywheel.
    The pressure plate applies pressure to the drive plate which is pushed against the flywheel. As the clutch pedal is
    progressively released, the friction between the drive plate, flywheel and pressure plate increases. The increase in
    friction transfers the rotary movement of the flywheel and pressure plate to the drive plate, which in turn starts to
    rotate the primary drive shaft. When the clutch pedal is released fully, the force applied by the diaphragm to the
    pressure plate forces the drive plate onto the flywheel with no slippage. 
    						
    							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 to9
    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. 
    						
    							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.PositionLRT-12-152alignment 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 to25 Nm (18 lbf.ft).
    10.Fit gearbox assembly.See MANUAL
    GEARBOX, Repair. 
    						
    							33CLUTCH
    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 to10 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. 
    						
    							CLUTCH
    3
    REPAIR
    5.Disconnect multiplug from clutch pedal sensor.
    6.Disconnect muliplug and harness clip from pedal
    bracket.
    7.Position cloth to collect fluid spillage.
    8.Loosen pipe union, release pipe and plug pipe
    and master cylinder.
    9.Move brake master cylinder assembly aside and
    lift out clutch master cylinder assembly.
    10.Remove 6 screws, remove pedal box top cover
    and discard gasket.
    11.Remove nut securing push rod to clutch pedal
    trunnion.
    12.Remove 2 bolts and remove clutch master
    cylinder from pedal bracket.
    13.Remove clutch pedal sensor and pipe union
    from master cylinder and discard sealing
    washers.Refit
    14.Clean sensor and pipe union.
    15.Fit clutch pedal sensor and pipe to master
    cylinder using new sealing washers.
    16.Position master cylinder to pedal bracket and
    align push rod to pedal trunnion.
    17.Fit bolts and nuts and secure master cylinder to
    pedal bracket.
    18.Fit nut securing push rod to clutch pedal trunnion
    but do not tighten nut at this stage.
    19.Move brake master cylinder aside and position
    clutch master cylinder assembly.
    20.Clean clutch pipe union.
    21.Align pipe and tighten union.
    22.Connect multiplug to clutch pedal sensor.
    23.Tighten bolts securing clutch pedal and brake
    pedal brackets to body.
    24.Fit clutch pedal rubber.
    25.Position closing panel and tighten screws to
    lower’A’post. 
    						
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