300Tdi Defender
33
CLUTCH
2
REPAIR
MASTER CYLINDER
Service repair no - 33.20.01/03
NOTE: All hose and pipe connections and
joints should be tightened to
15 Nm (11
lbf/ft).
Remove
1. Drain hydraulic fluid from system.
2. Disconnect fluid pipe at master cylinder. Plug
master cylinder fluid port and seal end of
hydraulic pipe to prevent ingress of dirt.
3. On RH drive vehicles, unclip air cleaner retaining
straps, disconnect bottom hose, and move
assembly aside.
4. From inside vehicle, remove fibre board closing
panel above pedals.
5. Remove 6 bolts securing pedal bracket to
bulkhead.
6. Remove screw securing speedometer cable
retaining bracket to top of pedal bracket.
7. Move pipework and cables aside and lift out
pedal bracket, complete with master cylinder,
turn through 90
°
to ensure pedal clears aperture
in bulkhead.
8. Remove 6 screws and detach pedal box top
cover and gasket.
9. Remove nut and washer securing master
cylinder push rod to clutch pedal trunnion.
10. Remove 2 nuts and bolts and withdraw master
cylinder from pedal bracket.
Refit
11. Fit master cylinder to pedal bracket, engaging
cylinder push rod through pedal trunnion.
12. Secure push rod to pedal trunnion.
13. Apply sealant to mating surfaces and fit pedal
bracket to engine bulkhead.
14. Connect fluid pipe to master cylinder.
15. Bleed clutch hydraulic system
See Bleed
hydraulic system .
16. Check and adjust clutch pedal and master
cylinder setting
See Adjustment, Clutch pedal
and master cylinder setting .
17. Fit top cover and gasket to pedal bracket.
18. On RH drive vehicles, refit air cleaner.
