gearbox LAND ROVER DISCOVERY 2002 Manual PDF

CLUTCH - TD5
33-1-8 DESCRIPTION AND OPERATION
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.
Pressure plate
1Leaf spring
2Drive plate
3Pressure plate
4Cover
5Diaphragm
6Rivet

CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-9
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.
Drive plate
1Friction material
2Inner plate
3Hub
4Spring 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.

CLUTCH - TD5
REPAIRS 33-1-13
REPAIRS
Clutch assembly
$% 33.10.01
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
2.Restrain flywheel.
3.Working in diagonal sequence, progressively
loosen 6 nuts securing clutch cover to flywheel.
4.Remove clutch cover and clutch plate.
5.Renew all worn or damaged components.Refit
1.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
2.Position clutch plate to flywheel with 'gearbox
side' facing towards gearbox.
3.Position tool LRT-12-152 through drive plate
into spigot bearing in crankshaft.
4.Fit clutch cover and locate on dowels.
5.Fit clutch cover nuts and progressively tighten
in diagonal sequence to 25 Nm (18 lbf.ft).
6.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.

CLUTCH - TD5
REPAIRS 33-1-15
Bearing and lever - clutch release
$% 33.25.12
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release lever.
Remove retaining clip and clutch release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip ensuring it locates over
release bearing pivot point washer, fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - Diesel.
Slave cylinder
$% 33.35.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.

+ CLUTCH - Td5, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-3
1Brake/clutch reservoir
2Connecting hose
3Bolt 2 off
4Master cylinder
5Clutch pedal
6Gearbox housing
7Primary driveshaft
8Bolt 2 off
9Slave cylinder
10Bleed nipple
11Pressure plate
12Drive plate
13Flywheel
14Metal hydraulic pipes
15Ball spigot
16Clutch release bearing sleeve
17Bolt 2 off
18Pivot washer
19Release lever
20Release bearing
21Retaining clip
22Bolt
23Bolt

CLUTCH - V8
33-2-6 DESCRIPTION AND OPERATION
Description
General
The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The clutch requires no
adjustment to compensate for wear.
Hydraulic clutch
The hydraulic clutch comprises a master cylinder, slave cylinder and a hydraulic reservoir, which is also shared with
the braking system. The master and slave cylinders are connected to each other hydraulically by plastic and metal
pipes. The plastic section of the pipe allows ease of pipe routing and also absorbs engine movements and vibrations.
The master cylinder comprises a body with a central bore. Two ports in the body connect the bore to the hydraulic
feed pipe to the slave cylinder and the brake/clutch fluid reservoir. A piston is fitted in the bore and has an external
rod which is attached to the clutch pedal with a pin. Two coiled springs on the clutch pedal reduce the effort required
to depress the pedal.
The master cylinder is mounted on the bulkhead in the engine compartment and secured with two bolts. The cylinder
is connected to the shared brake/clutch reservoir on the brake servo by a braided connecting hose.
The slave cylinder is located on the left hand side of the gearbox housing and secured with two bolts. A heat shield
protects the underside of the cylinder from heat generated from the exhaust system. The slave cylinder comprises a
cylinder with a piston and a rod. A port in the cylinder body provides the attachment for the hydraulic feed pipe from
the master cylinder. A second port is fitted with a bleed nipple for removing air from the hydraulic system after
servicing. The piston rod locates on a clutch release lever located in the gearbox housing. The rod is positively
retained on the release lever with a clip.
Clutch mechanism
The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever and a release bearing. The
clutch mechanism is fully enclosed at the rear of the engine by the gearbox housing.
A clutch release bearing sleeve is attached in the gearbox housing with two bolts and located on two dowels. A spigot
with a ball end is formed on the release bearing sleeve and provides a mounting and pivot point for the clutch release
lever. A dished pivot washer is located on the ball of the spigot. When the release lever is located on the ball, the pivot
washer seats against the rear face of the release lever. A spring clip is located on the lever and the pivot washer and
secures the lever on the spigot. A small bolt retains the spring clip in position.
The release lever is forked at its inner end and locates on the clutch release bearing carrier. The outer end of the
release lever has a nylon seat which locates the slave cylinder piston rod. A second nylon seat, positioned centrally
on the release lever, locates on the ball spigot of the release bearing sleeve and allows the release lever to pivot freely
around the ball.
The clutch release bearing locates on the clutch release lever and the release bearing sleeve. The bearing is retained
on a carrier which has two flats to prevent the carrier rotating on the release lever. A clip retains the release lever on
the carrier. The bearing and carrier are not serviceable individually.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-9
The drive plate is of the spring centred type and is sandwiched between the pressure plate and the flywheel. The drive
plate has a splined hub which engages with the splines on the primary drive shaft from the gearbox. The hub is located
in an inner plate which contains six compression damper springs. A spring retainer plate and a disc adaptor are
secured together with stop pins which limit the angular deflection of the disc adaptor. Engine power is transmitted from
the disc adaptor to the damper springs. The damper springs then transfer the power to the retainer plate and the hub.
Friction washers are located between the hub, retainer plate and disc adaptor and provide further damping.
A spring steel plate is riveted to the disc adaptor and provides the attachment surface for the drive plate friction
material. The friction material comprises discs which are secured with rivets to each side of the plate. The rivets are
installed through recessed holes in the disc and emerge in recessed holes in the opposite disc. The drive plate is 267
mm (10.5 in) diameter and has a friction material manufactured from APTEC T385.

CLUTCH - V8
REPAIRS 33-2-13
REPAIRS
Clutch assembly
$% 33.10.01
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Restrain flywheel.
3.Working in diagonal sequence, progressively
loosen 6 bolts securing clutch cover to flywheel.
Remove bolts.
4.Remove clutch cover.
5.Remove clutch plate.
6.Renew all worn or damaged components.Refit
1.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
2.Fit LRT-12-001 to spigot bearing in crankshaft.
3.Fit clutch plate onto LRT-12-001, ensure side
marked 'flywheel side' is against flywheel.
4.Fit clutch cover and locate on dowels.
5.Fit clutch cover bolts and progressively tighten,
in diagonal sequence shown, to 40 Nm. (30
lbf.ft).
6.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.

CLUTCH - V8
REPAIRS 33-2-15
Bearing and lever - clutch release
$% 33.25.12
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release lever.
Remove retaining clip and remove clutch
release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip, ensuring it locates over clutch
release lever pivot point washer. Fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Slave cylinder
$% 33.35.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-1
MANUAL GEARBOX - R380 DESCRIPTION AND OPERAT ION
R380 gearbox