TD5 Defender
CLUTCH
3
REPAIR
5. Disconnect multiplug from clutch pedal sensor.
6. Disconnect muliplug and harness clip from pedal
bracket.
7. Position cloth to collect fluid spillage.
8. Loosen pipe union, release pipe and plug pipe
and master cylinder.
9. Move brake master cylinder assembly aside and
lift out clutch master cylinder assembly.
10. Remove 6 screws, remove pedal box top cover
and discard gasket.
11. Remove nut securing push rod to clutch pedal
trunnion.
12. Remove 2 bolts and remove clutch master
cylinder from pedal bracket.
13. Remove clutch pedal sensor and pipe union
from master cylinder and discard sealing
washers.
Refit
14. Clean sensor and pipe union.
15. Fit clutch pedal sensor and pipe to master
cylinder using new sealing washers.
16. Position master cylinder to pedal bracket and
align push rod to pedal trunnion.
17. Fit bolts and nuts and secure master cylinder to
pedal bracket.
18. Fit nut securing push rod to clutch pedal trunnion
but do not tighten nut at this stage.
19. Move brake master cylinder aside and position
clutch master cylinder assembly.
20. Clean clutch pipe union.
21. Align pipe and tighten union.
22. Connect multiplug to clutch pedal sensor.
23. Tighten bolts securing clutch pedal and brake
pedal brackets to body.
24. Fit clutch pedal rubber.
25. Position closing panel and tighten screws to
lower ’A’ post.