Clutch assembly/driven disc and release bearing (throw-out bearing) — Td4 (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the gearbox.

MECHANICAL GEARBOX - GETRAG, Rear cover, Gearbox.

3. Place a flat disc on the petals of the diaphragm spring and check the gap between the petals and the disc with a feeler gauge. If the specified limit is exceeded only on one petal, then this is acceptable. Gap value: The operating limit is 1.0 mm.



4. Install the LRT-12-177 tool on the crankshaft.



5. While holding the crankshaft, loosen and remove the 6 clutch housing mounting bolts.





6. Remove the clutch cover and driven disk.



7. Measure the thickness of the driven disk, replace the driven disk if its thickness is less than the permissible. Thickness of the driven disk (compressed) A: New disk = 7.5 mm. Minimum permissible thickness = 5.9 mm.

8. Measure the rivet recess, replace the driven disc if the recess is less than the permissible value. Rivet recess B: New disc = 1.2 mm. Minimum permissible recess = 0.2 mm.

9. Check the pressure plate for wear or damage. Check for tarnish on the contact surface (from dark yellow to blue), replace the plate if necessary.

NOTE: Replace the pressure plate if it is accidentally dropped.

10. Using a straightedge and feeler gauge, check the disc surface geometry at four different points. Replace the disc if the warpage exceeds the permissible value. Pressure plate warpage: The service limit is 0.15 mm.





11. Release the bushings holding the clutch drive tubes.



12. Remove the release bearing.

13. Check the release bearing for wear or damage and replace if necessary.

Installation

1. Clean the release bearing guide sleeve.

2. Lubricate the release bearing guide bushing with molybdenum disulfide grease.

3. Install the release bearing and secure the clutch drive tube sleeve.

4. Clean the pressure plate, flywheel, mounting pins and holes for them.

5. Check the flywheel running surface for scoring or other damage. Replace the flywheel if the running surface is damaged or worn.

6. Lubricate the splines of the driven disk with molybdenum disulfide grease.

7. Place the driven disc on the pressure plate with the 'GEARBOX SIDE' marking facing the gearbox.





8. Using the LRT-12-162 drift, center the driven disk.



9. Check the quality of the centering of the driven disk in relation to the pressure disk.

10. Install the clutch assembly onto the flywheel and place it onto the mounting pins.



11. Screw in the clutch housing mounting bolts and tighten them, crosswise, to a torque of 25 Nm.



12. Remove the LRT-12-162 centering mandrel.

13. Install the gearbox.

MECHANICAL GEARBOX - GETRAG, Rear cover, Gearbox.

14. Connect the negative battery terminal.