clutch LAND ROVER FRELANDER 2 2006 Service Manual

5. CAUTION: Di scard the bolt s .
• NOTE: Loosen the bolt s of t he cl utch pres s ure pl ateeach two turns at a t ime in t he s equence s hown.
• NOTE: Res train t he flywheel .
5.
Installation
1. NOTE: The cl utch cover i s s elf adjus ti ng. It i srecommended t hat a cl utch di sc and cl ut ch cover isrepl aced as an as s embly. If a us ed cl utch cover i sas sembl ed wit h a new clutch di sc, t he clutch coveradjus tment must be res et prior t o as sembl y. W it h t heclut ch cover support ed under i ts out s ide edge, pressdown evenl y on t he diaphragm fi ngers as s hown, unt ilt he clutch cover adjus t ment ri ng can be rot ated full ycount erclockwis e. W it h t he adjus tment ring hel d in thi spos it ion, releas e t he pres s ure on t he diaphragmfingers . The adjus tment ring wi ll be held in t hispos it ion unti l sel f adjust ment on t he appl icati on of theclut ch pedal.
Check, and i f necess ary, reset t he clut ch press ureplat e.
1.

Publi s hed: 12-May-2011
Clutch Controls -
Torque SpecificationsDescriptionNmlb-ft
Clut ch bleed s crew107
Clut ch pedal box nuts2418Clut ch s lave cyl inder bol ts118

Publi s hed: 11-May-2011
Clutch Controls - Clutch Controls
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Brake/clut ch res ervoir
2-Brake mas ter cylinder
3-Connector4-Low pres sure hos e
5-Clutch pedal bracket
6-Clutch mas t er cyli nder7-High pres s ure hos e
8-Connector
9-Clutch s l ave cyli nder and release bearing10-Hydraul ic adaptor and peak torque li mit er
11-Bleed s crew
12-Clutch pedal13-Brake pedal
OVERVIEW
The clutch i s a convent ional si ngl e, damped driven pl at e and a sel f-adjust ing di aphragm s pri ng clutch cover as s embly

which i s hydraulicall y act uated from t he cl utch pedal.
Pres s ing t he clutch pedal pres surizes t he hydraul ic fluid in the mas t er cyli nder. The fl uid pres s ure is t rans ferred via a pipefrom the mas t er cyli nder t o t he s lave cyl inder in the t rans mis s ion. The fluid press ure operates t he s lave cylinder which i nt urn pus hes the fingers of t he clut ch cover, rel easi ng the driven pl at e and di sengagi ng t he dri ve from t he engi ne crankshaftt o the trans mi s si on.
A hydrauli c clutch bl eed adapt or i s l ocated on the front of t he transmis s ion. The adapt or provi des the connect ion betweent he pres sure pipe from t he mas ter cyl inder to the s l ave cyli nder. The adapt or contains a bleed s crew to purge t he cl utchhydraulic sys tem of air aft er s ervice repl acement of one of the hydrauli c components. The adaptor als o i ncl udes a peakt orque li mit er. This prevent s ins t ant clut ch engagement if t he dri ver accident all y rel eas es t he clutch l ever t o preventdamage to the driveli ne components .
Stop/Start Vehicles - From 2010 MY
Clut ch Mast er Cyl inder and Linear Cl utch Sensor
The li near clut ch s ens or, l ocat ed on t he cl utch mas t er cyli nder and hardwi red t o t he CJB, i s us ed to s ens e t he posi ti on oft he cl utch pedal. It is us ed in conjunct ion wi th ot her sens or out puts t o t ri gger an engine res tart, engine s t op or st allrecovery on St op/Start vehi cl es. It is al s o us ed along wit h t he first and revers e gear s wi tches to compl ete cl ut chplaus ibil it y.
A magnet ins ide the clut ch mas ter cylinder provides t he posi ti on indicator for the linear cl utch s ensor. For t his reason, ift he mas ter cyl inder is replaced the correct replacement mas t er cyli nder mus t be i dent ified and fit t ed.For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
Linear Clutch Sens or

Publi s hed: 11-May-2011
Clutch Controls - Clutch Controls
Diagnosi s and Tes ti ng
Principles of Operation
For addit ional informat ion.REFER to: Manual Transaxle and Clutch (308-00 Manual Transmis si on/Trans axl e and Cl ut ch - General Informat ion,Diagnosi s and Tes ti ng).

Publi s hed: 11-May-2011
Clutch Controls - Clutch Slave Cylinder
Removal and Inst all ati on
Removal
• NOTE: The clut ch sl ave cyli nder and releas e bearing are a combined as s embly and ca nnot be servi ced separat ely.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he transmis si on as sembl y.
Refer t o: Transmis s ion (308-03 Manual Trans mi s si on/Trans axl e,
Removal).
3. 4. CAUTION: If brake fl ui d i s s pi lt on the paint work,
the affect ed area mus t be i mmediat ely was hed down wit h
col d wat er.
T orque: 11 Nm 4.
Installation To i nst all , revers e t he removal procedure.
1.
Bleed t he clut ch sys t em.
Refer t o: Clutch Sys tem Bleeding (308-00 Manual
Trans mi ss ion/Transaxle and Clut ch - General Informati on, General
Procedures ).
2.
Inst all t he transmis si on.
Refer t o: Transmis s ion (308-03 Manual Trans mi s si on/Trans axl e,
Removal).
3.
Connect t he batt ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
4.

Publi s hed: 11-May-2011
Clutch Controls - Clutch Master CylinderRHD AWD
Removal and Inst all ati on
Removal
Remove t he cl utch pedal as s embly.
Refer t o: Clutch Pedal - RHD AW D (308-02 Clut ch Cont rol s, Removaland Inst all at ion).
1.
Installation
Inst all t he cl utch pedal as s embly.
Refer t o: Clutch Pedal - RHD AW D (308-02 Clut ch Cont rol s, Removaland Inst all at ion).
1.

Publi s hed: 11-May-2011
Clutch Controls - Clutch Master CylinderLHD AWD
Removal and Inst all ati on
Removal
Remove t he cl utch pedal as s embly.
Refer t o: Clutch Pedal - LHD AW D (308-02 Clutch Cont rols , Removaland Inst all at ion).
1.
Installation
Inst all t he cl utch pedal as s embly.
Refer t o: Clutch Pedal - LHD AW D (308-02 Clutch Cont rols , Removaland Inst all at ion).
1.

Publi s hed: 11-May-2011
Clutch Controls - Clutch PedalRHD AWD
Removal and Inst all ati on
Removal
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
Remove t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - TD4 2.2L Dies el(501-02 Front End Body Panel s, Removal and Ins tal lati on).
2.
3. CAUTION: Brake flui d wil l damage pai ntfinis hed s urfaces . If s pil led, immedi ately remove t hefluid and cl ean the area wit h wat er.
• NOTE: Pos it ion clot h t o col lect fl uid s pil lage.
3.
4. NOTE: If equiped4.
Remove t he dri ver l ower ai r bag.
Refer t o: Dri ver Lower Air Bag Module (501-20B SupplementalRes traint Sys t em, Removal and Inst all at ion).
5.

14.
Installation
1. CAUTION: "Make sure t hat a new component isi ns t alled. "1.
To i nst all , revers e t he removal procedure.2.
Bleed t he clut ch sys t em.
Refer t o: Clutch Sys tem Bleeding (308-00 ManualTrans mi ss ion/Transaxle and Clut ch - General Informati on, GeneralProcedures ).
3.