Adjusting the free travel of the clutch pedal (Defender 2007+)

General procedures

1. Remove 6 screws and remove the pedal box top cover and gasket.

2. Loosen both locknuts on the master cylinder pushrod.

3. Check the distance from the bottom edge of the clutch pedal to the floor. The correct size is 140 mm (5.50 inches) without a floor mat.



4. If necessary, adjust the pedal stop to achieve the correct setting.

5. Adjust the master cylinder tappet to obtain a clearance of approximately 1.5 mm between the master cylinder piston and the tappet (1/16 inch).

6. Tighten the pushrod locknuts.

7. Check the operation of the clutch pedal and make sure that there is at least 6 mm of clearance before resistance occurs (0.25 inches). Adjust the master cylinder tappet if necessary.

8. Install the top cover and gasket onto the pedal bracket.

9. On right-hand drive vehicles, install an air filter.