Land Rover Defender Workshop 1993 Rover Manual

							OVERHAUL RELEASE BEARING ASSEMBLY 
OVERHAUL MASTER CYLINDER - All models 
1. Remove  the clutch  slave cylinder  from the bell Dismantle 
2. Withdraw  the  retaining staple, if fitted. 1. Remove the master  cylinder from the vehicle. 
3. Remove  the release  bearing assembly. 2. Remove  the circlip. 
4. Remove  spring clip  retaining  bolt and spring. 3. Withdraw the push-rod and  retaining  washer. 
5. Withdraw  the  release lever. 
6. Discard  worn parts. 
7. Smear  the pivot  with  grease  and fit the 
release  lever and retain  with the spring  clip 
and  bolt. 
8. Smear  the release  bearing  sleeve  inner 
diameter  with  Molybdenum  disulphide  base 
grease. 
9. Fit  the  release bearing  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. 
housing. 
4. Withdraw 
the piston  assembly. If necessary, 
apply  a low  air pressure 
to the  outlet port to 
expel the  piston. 
10. Coat both sides  of the  backing  plate with a 
waterproof  joint compound  such  as Hylomar 
PL32M  and locate  the backing  plate  and  dust 
cover  in position  on the  slave cylinder. 
11.  Check  that the push
-rod  clip  is in  position. 
12.  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,  tighten  evenly to the 
correct  torque.  
						

							CLUTCH 
5. Prise the locking  prong of the spring  retainer Assemble 
clear of the piston  shoulder  and  withdraw  the 
piston. 
14. Smear  the seals  with  rubber  grease  and  the 
remaining  internal  items  with brake  and clutch 
stem  to align  with the  larger  hole in the spring 
15. Fit  the  valve  seal, flat side  first,  onto  the  end 
retainer  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. 
6. Withdraw  the  piston seal. 
7.  Compress  the  spring and position  the valve  fluid. 
8. Withdraw the  spring  and  retainer. 
from  the valve  stem. 
9. Withdraw  the  valve spacer and  spring  washer 
18. Place the coil  spring  over  the valve  stem. 
20. Compress  the  spring  and engage  the valve 
stem 
in the  keyhole  slot in the  retainer. 
10. Remove  the valve  seal. 19. Insert the  retainer into the spring. 
Inspection 
11. Clean all components in 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  replacements. 
13. The  seals  should be replaced with new 
21. Fit the  seal, large  diameter last, to the  piston. 
22. Insert  the piston  into  the  spring retainer  and 
engage the locking prong. 
components.  
						

							CLUTCH 
OVERHAUL SLAVE CYLlNDER 
Dismantle 
1 . Remove the  slave cylinder from the vehicle. 
3. Expel  the  piston  assembly, applying low 
4. Withdraw the spring. 
2. Withdraw the dust  cover. I 
pressure air  to the  fluid  inlet. 
5. Prise off the seal  from  the  piston. I 
23. Smear the  piston  with  rubber  grease and 
insert  the  assembly,  valve  end first,  into  the 
cylinder. 
24. Fit the  push-rod,  retaining  washer  and  circlip. 
Inspection 
6. Clean all components  with  cleaning  fluid and 
allow 
to dry. 
7. 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  replacement. 
8. The seal  should  be  replaced  with a new I 
component. 
Assemble 
9. Smear  the seal  with rubber  grease  and the 
remaining  internal  items  with  brake and clutch 
fluid. 
10. Fit the seal,  large diameter  last, to the piston. 
11. Locate the  conical  spring,  small  diameter first, 
over  the  front  end of the  piston. 
12. Smear the  piston  with rubber  grease  and I 
insert the  assembly,  spring  end first,  into the 
cylinder. 
13. Fill  the  dust  cover  with  rubber  grease  and fit 
the cover to the cylinder.  
						

							CLUTCH 
CLUTCH PEDAL AND MASTER  CYLINDER  BLEED CLUTCH  HYDRAULIC  SYSTEM 
ADJUSTMENT 
When  the gearbox  and bell 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 
Adjust  into 
the system.  Use only  the fluid  recommended 
in  the  Lubrication  chart. Use only  new fluid  from 
2. Withdraw  the six screws  and remove  the top a sealed  container. 
plate. 
3. Slacken  master  cylinder  push-rod  locknuts  to 1. Attach a length  of suitable  tubing to the  slave 
provide  free  movement 
of the push-rod  cylinder  bleed  screw  and immerse the free 
through the pedal trunnion.  end of the  tube  in a glass  jar  containing  new 
4. Slacken the  adjustment  screw locknut.  clutch fluid. 
5. To increase  the  pedal  height, turn the 2. Slacken  the bleed  screw  and  depress  the 
adjustment  screw anti
-clockwise.  To reduce  clutch  pedal, pausing at the  end of each 
turn  clockwise.  stroke, 
until the fluid  issuing  from  the  tubing  is 
When  correct tighten  the  locknut.  free of air  with  the  tube  free  end  below the 
6. To adjust  the master  cylinder  push-rod, check  surface of the  fluid in the container.  Whilst 
that  the push
-rod has  free-play  through  the  holding  the  clutch  pedal down  and  with  the 
trunnion. 
free end  of the  tube  below  the fluid,  tighten 
7. Adjust the locknuts until the push-rod  has 1,5 the bleed  screw. 
mm  free
-play  between  the  push-rod  and 
master  cylinder.  When correct  tighten  the 
locknuts. 
8. Check  that there is 6 mm free  movement  of 
the  pedal  at  the  pad. 
If necessary re-adjust 
the  push
-rod. 
9. Refit  the  top  plate. 
1. The correct  height for the  clutch  pedal from 
the  floor  of the  footwell,  without a mat, 
to the 
lower  edge of the  pedal is 
140 mm,  dimension 
A.  
						

							CLUTCH 
RENEW  CLUTCH SLAVE CYLINDER  RENEW 
CLUTCH  MASTER  CYLINDER 
Left 
hand drive  vehicles 
To Remove 
1. Evacuate  clutch system  fluid at slave  cylinder  2. Remove  the bonnet. 
2. Disconnect  fluid pipe.  cylinder to the 
the  servo. 
3. Remove two securing  bolts and  withdraw 4. Carefully  ease  the  master cylinder  away from 
the  servo  without  imposing  any strain  upon 
the  brake fluid  pipes. 
4. If dust  cover is  not withdrawn  with slave 5. Disconnect  the  vacuum hose  from  the  servo 
and  move  aside. 
6. Disconnect the two brake  lamp  lucars. 
7. From inside  the vehicle,  remove  the  fibre 
board closing  panel  above the  pedals. 
8. Release  the two return springs  from the brake 
pedal  and single  spring  from  the clutch pedal. 
9. Remove  the six bolts  securing  the brake  pedal 
box  to  the  bulkhead  and carefully  withdraw 
the  pedal  box with  the servo  sufficiently  to 
allow  clearance  for  the clutch master  cylinder 
and  pedal  box 
to be withdrawn. 
10. Remove  the SIX bolts  securing  the clutch 
pedal  box 
to the bulkhead. 
bleed  valve. 
3. Remove 
the two nuts securing  the  master 
slave  cylinder  and backing  plate. 
cylinder,  withdraw  it from  bell housing. 
To Refit 
5. Withdraw  dust  cover and backing  plate  from 
slave  cylinder. 
6. Coat  both sides  of backing  plate with  Hylomar 
P232M  waterproof  jointing compound. 
7. Locate  backing  plate and  dust  cover in 
position on  slave cylinder. 
8. Fit slave  cylinder,  engaging  push rod through 
centre  of dust  cover  and with  bleed  screw 
uppermost. 
9. Reconnect  fluid pipe. 
11. Release  the  hydraulic  pipe  from the dutch 
master cylinder  and  cover  the end. 
12.  Remove  the clutch  pedal  and  master cylinder 
assembly from  the vehicle. 
13.  Remove  the  reservoir  cap and  discard  the 
fluid. 
14.  Remove  the six screws  and lift-off  the pedal 
box  top cover  and gasket. 
15.  Remove  the two  nuts  and bolts  that secure. 
the  master  cylinder  to the  pedal  box: 
16.  Remove  the  nut and washer  from the end  of 
the master  cylinder push rod. 
17.  Withdraw  the master  cylinder  and steel 
gasket. 
18.  Fit the  two  locknuts  and plain  washer  to the 
10.  Replenish  and bleed clutch  system. 
11.  Check  for  fluid  leaks  with pedal  depressed  push
-rod. 
and  also  with system  at rest. 
1.  Disconnect  the  battery.  
						

							CLUTCH 
Refitting 
19. Fit the master cylinder  and steel  gasket to the 
pedal  box and insert  the  push
-rod through  the 
bush  and trunnion  and loosely  fit 
the single 
nut 
to the  end of the push-rod. 
20. Secure  the master  cylinder  with  the  two nuts 
and  bolts to  the pedal  box. 
21.  Fit the  pedal  box to the  bulkhead  resealing 
with  Bostic  adhesive  and  secure  with the six 
bolts. 
22.  Check  the clutch  pedal height  and  free
-play, 
adjust  if necessary.  Tighten the push
-rod  end 
nut.  Connect  the return  spring  to the  pedal. 
23.  Fit the  pedal  box top cover  with  a new  gasket 
and  secure  with the six  screws. 
24.  Connect  the fluid  pipe  to the  master  cylinder. 
25.  Fit the  brake  servo and pedal  box assembly, 
reseal  with Bostic  adhesive  and secure  with 
the  six bolts. 
26.  Connect  the return  springs  to the pedal. 
27.  Fit  the  brake master  cylinder  to the  servo  and 
tighten  the two  nuts, 
28.  Fit the  fibre  board  closing  panel. 
29.  Connect  the stop  lamp lucars. 
30.  Attach  the three  way pipe  union  bracket  to the 
servo  (90 models). 
31.  Connect  the vacuum  hose to the  servo. 
32.  Fill  the  clutch master  cylinder  with new fluid 
from  a sealed  container  of the 
recommmended  grade to  the  level mark on 
the  side  of the  reservoir. 
33.  Bleed  the clutch  hydraulic  system and fit the 
reservoir cap. 
34.  Connect  the battery,  fit the  bonnet  and  road 
test  the vehicle.  
						

							LT77S MANUAL GEARBOX 
REMOVE LT77S  MANUAL  GEARBOX  AND LT230 11. Release the air filter hose at filter. 
TRANSFER BOX 12. Raise  the ramp. 
13. Remove  the eight  nuts and bolts  securing  the 
WARNING: Where the  use of a transmission  chassis  cross member and using a suitable 
hoist 
is necessary, it is absolutely  essential  to means of spreading  the  chassis,  remove the 
follow 
the manufacturers  instructions to ensure  cross member. 
safe  and effective  use of the  equipment.  14. Place  a suitable  container  under  the 
transmission,  remove the three  drain  plugs, 
allow  the oil to drain  and refit the  plugs.  Clean 
filter  on the  extension  housing  plug before 
refitting. 
15. Remove  the  intermediate exhaust pipe  and 
silencer  section  as 
follows: 
(a) Release  the  connection  to the  front  pipe 
at  the flange. 
(b)  Release the  connection 
to the rear  section 
at  the  flange  immediately  behind  the 
silencer. 
(c)  Remove  the 
U bolt retaining  the pipe to 
the  bracket  attached to the  transfer  box. 
16. Mark the flanges  for reassembly  and 
disconnect  the  front propeller shaft  from  the 
transfer  box. 
17. Similarly,  disconnect  the rear  propeller shaft. 
18. Disconnect  the  speedometer  cable from the 
rear 
of the  transfer  box. 
19. Disconnect  the  handbrake  inner  cable  by 
removing  the  split pin and  clevis  pin. 
20. Slacken  the  retaining  nuts  and release the 
handbrake  outer  cable  from the bracket. 
21. Remove  the two  bolts  and withdraw  the  clutch 
slave  cylinder  from the bell  housing. 
22. Manufacture  a cradle to the  dimensions given 
in the  drawing  and attach  it to a transmission 
hoist. 
To achieve  balance  of the  transmission 
unit  when  mounted  on the  transmission  hoist, 
it is essential  that point A is situated  over the 
centre 
of the  lifting  hoist  ram. Drill  fixing  holes 
1. Install  the vehicle on  a ramp. B to  suit  hoist  table.  Secure the transmission 
2. Disconnect the  battery. 
unit to the  lifting  bracket  at point C, by  means 
3.  Remove  the gear  lever  knob.  of the  lower  bolts  retaining the  transfer 
4. Remove the transfer  and differential  lock  gearbox rear  cover. 
knob. 
23. Remove  the bottom two bolts from the  transfer 
5. Remove the  gear  lever cover. 
box rear  cover  and use them to attach  the 
6. Remove  the 10 mm  Nyloc  nut and  plain  rear end of the  cradle  to the  transfer  box. 
washer.  Mark the gear  lever  spline  setting  and 
Ensure  that  the  tube in the  centre 
of the 
detach  the  gear  lever and gaiter  from  the  cradle  locates  over the  extension  housing 
splined  lower  gear  lever.  drain plug. 
7. Select  high  range to prevent  the transfer 24. Raise  the hoist  just  enough  to take  the weight 
gearbox  selector  lever  fouling the tunnel  when  of the  transmission. 
removing  the  gearbox. 
25. Remove  the three  nuts  and bolts  securing  the 
8. Remove the bonnet. 
transfer box LH and R H mounting  brackets 
9. Remove the nuts  and bolts  retaining  the fan to the  chassis. 
Cowl  to  the  engine  and move  the cowling 
26. Remove  the nuts  retaining  the brackets  to the 
forward, clear of the  engine. 
speedometer  cable, and starter  motor  harness 
from  clips at rear  of the  engine.  mounting 
rubbers and remove  the  brackets. 
10.  Release  the  transmission breather  pipes, 
27. Lower the  hoist  sufficiently  to  allow the 
transfer  lever 
to clear  the  transmission  tunnel 
aperture. 
28. Disconnect  the  four-wheel drive  indicator 
electrical  lead  (bullet  connection).  
						

							LT77S MANUAL GEARBOX 
MATERIAL  AND WELDING  SPECIFICATION 
Steel Plate 
Tube 
BS 4848  (Part 2) 
BS 1449 (Grade 4  or 14) 
Arc  Welding BS 5135 
operating  rod. 
29.  Remove  the cleat  retaining  the  reverse  light 
40. Remove the breather  pipes. 
switch  wires from the 
RH side of the 
gearbox. 
30.  Disconnect  the  wire  from the reverse  light 
switch  situated  at the  top  rear 
of the  selector 
housing  and move  the  harness away from  the 
transmission. 
31.  Support  the engine  under  the sump  with a 
jack,  placing  timber between 
the jack  pad  and 
sump. 
32.  Remove  the eleven  bell housing  nuts. 
33. Withdraw  the transmission  whilst  ensuring  all 
connections  to  the engine  and  chassis  are 
released. 
Separating  the transfer box from  gearbox 
34. 
Remove  the transmission  assembly  from  the 
hoist  and cradle  and install  it safely  on a 
bench. 
35. Remove  the four  bolts  securing  the  transfer 
gear  change  housing  to  the  remote gear 
change  housing. 
36. Remove  the two bolts retaining  the cross  shaft 
lever  pivot bracket  to the  extension  housing. 
37. Release  the connecting  link from  the 
differential 
lock lever. 
38.  Disconnect  the pivot  arm from  the high/low 
shaft. 
39  Remove  the lower  lockout  from the high/low  
						

							LT77S MANUAL GEARBOX 
41. Hoist  the transfer  box into  position  ensuring 
that  the  loose  upper dowel  is fitted,  Assemble 
to 
the main  gearbox  extension  housing  and 
secure  with  the four  bolts  and 
two nuts. 
42.  Reverse  instructions 
37 to 40. 
59. Check  that  the  three drain plugs  are tight  and 
remove  the main  gearbox  and  transfer box 
filler  level  plugs.  Fill the  main  gearbox with a 
recommended 
oil until it begins  to run  out of 
the  filler  level hole.  Fit and  tighten  the filler 
plug.  Similarly  remove the transfer 
filler  level 
plug  and inject  a recommended oil  until  it  runs 
out  of the  filler  hole. Apply  Hylosil  to  the 
43.  Fit the  cradle to the  transmission  hoist and the  threads 
and fit the plug and  wipe  away  any 
transmission to the  cradle  as described  in  surplus oil. 
instruction  23.  Smear  Hylomar on bell  housing  60. 
Line up the  marks  and 
fit the  front and rear 
face  mating  with engine.  propeller shafts 
to the  transfer  box. 
44.  Locate  the  gear  lever 
temporarily and select  61. Fit the  exhaust  system, and evenly  tighten  the 
any  gear  in the  main  gearbox 
to facilitate  flange  nuts and bolts.  Fit  the U bolt and 
entry  of the  primary  shaft.  secure 
to the  bracket. 
45.  Position  and  raise hoist and 
fit the  62. Expand  the  chassis side  members,  fit  the 
transmission 
to the  engine  whilst keeping  cross  member and  secure  with the  eight  nuts 
wires  and pipes clear  to  prevent trapping. 
46.  Secure  the transmission 
to the  engine  with  the 
eleven  nuts,  noting that the top  RH  nut holds 
a 
clip  for the  speedometer  cable. 
47.  Position  the  reverse 
light wires to the RH 
side  of the  main  gearbox  and secure  with a 
cleat 
to the  breather pipes. 67. Fit main gear  lever  gaiter  and lever, to 
48. Connect  the  reverse light wire to the  switch  at  previously  marked  spline 
setting. Secure  with 
the  top  rear  of the  selector  housing. 
the 
10 mm Nyloc  nut (with  plain washer) to 
49, Connect  the  differential lock  indicator  wires  the  correct  torque. 
(bullet  connection). 
68. Fit the cover  to both  gear  levers  and the 
50. Raise  the transmission to line-up with  the  knobs. 
engine  and ensure  that the  transfer  lever 
clears  the tunnel  aperture. 
51.  Fit  the  transfer  box LH and  RH mounting 
brackets  but only part ially 
tighten  the  securing 
nuts  and bolts. 
52. Loosely fit the rubber  mounting  nuts and  lower 
the  transmission 
onto the  mountings.  Fully 
tighten  all the securing nuts  and  bolts. 
53. Remove the supporting  jack from  under  the 
engine  sump. 
54. Remove  the two bolts securing  the cradle to 
the  transfer box and  remove  the cradle  and 
hoist. 
55. Refit  the two bolts  using  Loctite  290 on the 
threads  and note  that the 
L H bolt  holds  a clip 
for  the  speedometer  cable. 
56.  Fit the  slave  cylinder  using  Hylosil 
on the 
gasket  and tighten  the  two  bolts  evenly to 22 
to  28  Nm. 
57. Fit  the  handbrake  cable using a new  split pin 
to secure  the  clevis  pin.  Grease the clevis  and 
tighten  the outer  cable  lock  nuts. 
58.  Connect the  speedometer cable. 
Fitting  main gearbox  and transfer  box to engine 
64.  Clip  the  breather  pipes,  speedometer  cable 
and  starter  motor  harness 
to rear of engine. 
65. Fit the  fan  cowl. 
66.  Fit  the  bonnet. 
and bolts (four each side). 
63.  Fit the heater pipe clamp.  
						

							DISMANTLE 
Bell housing 
1. Remove clutch release bearing. 
2. Remove  screw and spring  clip  and remove 
release lever. 
3. Remove  C clip  from  pivot post. 
4. Remove six bolts  and bell housing. 
EXTENSION  HOUSING 
1. Remove snap ring retaining  oil seal  collar. 
GEAR  SELECTOR  HOUSING 
1. Remove four bolts  and remove  main  gearbox 
selector  housing. 
2. Remove transfer  box housing. 
3.  Remove  remaining 
bolts and remove  remote 
housing. 
4. Drive  out quadrant  roll  pin. 
5. Move  selector  shaft  forward  to remove 
quadrant.