Dual mass flywheel - material specification

DUAL MASS FLYWHEEL - MATERIAL SPECIFICATION

Model

Discovery II

Reference

Recall action 211

Bulletin text

RECALL ACTION BULLETIN

Circulation: X Indicates to whom this information should be circulated SERVICE MANAGER X SERVICE RECEPTION PARTS MANAGER WARRANTY MANAGER

DEFENDER Td5 Manual gearbox derivatives DEFENDER Td5 CKD Manual gearbox derivatives

DISCOVERY Series II Manual gearbox derivatives

DISCOVERY Series II CKD Manual gearbox derivatives Engine number range Build date range

PROBLEM:

DUAL MASS FLYWHEEL - MATERIAL SPECIFICATION

CAUSE:

High energy inputs into the clutch and flywheel system may lead to structural failure of the flywheel assembly. The energy inputs may cause the flywheel to exhibit surface cracks, which under certain conditions could propagate, resulting in loss of drive due to the clutch slipping. In extreme conditions the flywheel could fragment resulting in extensive damage to the clutch bell housing.

ACTION:

To protect the long term integrity of the flywheel assembly Land Rover are implementing recall action on all Discovery and Defender Td5 manual models within the affected VIN range. All vehicles within the affected VIN range shown above will require the flywheel assembly to be replaced. Where necessary, after visual inspection, replacement of associated clutch parts may be required if consequential wear is noted. All vehicles currently held in stock, demonstrators and showroom vehicles must have the flywheel replaced prior to the vehicle being despatched to a customer.

PROCEDURE

DURING THE FLYWHEEL REPLACEMENT PROCEDURE, ASSOCIATED COMPONENTS MUST BE INSPECTED DETERMINE IF EXCESSIVE WEAR EXISTS. THE WORKSHOP MANUAL INSTRUCTIONS DESCRIBE THE WEAR CHARCATERISTICS THAT EACH OF THE COMPONENTS SHOULD BE EXAMINED FOR, AS SOME OF THESE COMPONENTS MAY NOT REQUIRE REPLACEMENT.

RECALL ACTION BULLETIN No: A/D211

EN Bull. N o : A/D211

AFFECTED RANGE:

XA145775 to YA181042 XF829247 to XF833265

XA200000 to YA244647 XA900000 to XA907209 XA920000 to XJ920147

10P00001a to 10P38890A September 1998 to June 1999

CLUTCH TO

Rover Group 2000

Reference should be made to the workshop manual for repair instructions when replacing the flywheel assembly.

It must be noted that zero mileage vehicles ie showroom/stock and CKD vehicles will only require the flywheel and fixings to be replaced.

THE FOLLOWING CARE CONJUNCTION WITH THE WORKSHOP MANUAL REPAIR PROCEDURE.

• If the flywheel face exhibits any surface cracks the clutch assembly must be replaced. • Flywheel bolts MUST be tightened to 40Nm (+) 90 degrees. • Remove the existing grease from the release bearing guide tube and replace with a THIN coating of Molibdium Disulphide grease. • Clean the fulcrum arm and nylon insert within the clutch release mechanism, remove any old grease and inspect for wear as described in the workshop manual, additionally if the fulcrum insert is loose or deformed in any way the fulcrum assembly MUST be replaced. If the original components are being replaced or renewed apply a small amount of Molibdium Disulphide grease to both components prior to re-asembly. • If a new clutch plate is being fitted ensure that the plate is free to travel along the constant pinion spline prior to fitment. • Clutch cover fixings MUST be tightened to 22 to 28 Nm. • Check the crankshaft spigot for scoring and uneven wear characteristics, if necessary replace the spigot bearing. • Road test the vehicle and check for clutch functionality. • Apply a white paint mark identification to the two bonnet lock fixings. Fig 1 Discovery, Fig 2 Defender.

• Endorse the service record book.

RECALL ACTION BULLETIN No: A/D211

POINTS MUST BE OBSERVED IN

Rover Group 2000

PARTS INFORMATION:

PSD103470K Flywheel 1 off ERR6581 Flywheel bolts 8 off FTC4630K Clutch cover 1 off FTC4631K Clutch driven plate 1 off NH108041L Clutch cover fixings 6 off 576137 Release arm 1 off 571161 Insert release arm 1 off FTC5200K Clutch release bearing 1 off 8566L Crankshaft spigot 1 off

WARRANTY CLAIMS: Complaint code UK = A211 Europe/Rest of World = D211

UK - Discovery Td5 Option code A- Flywheel and Fixings = 05.70 hours Option Code B -Flywheel /Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing = 05.70 hours Option code C - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert = 05.80 hours Option code D - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert/spigot bearing = 05.90 hours

Europe/Rest of World - Discovery Td5 12.53.89/29 - Flywheel and Fixings = 05.70 hrs 12.53.89/30 - Flywheel /Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing = 05.70 hours 12.53.89/31 - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert = 05.80 hours 12.53.89/32 - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert/spigot bearing = 05.90 hours

UK - Defender Td5 Option code E- Flywheel and Fixings = 06.70 hours Option Code F -Flywheel /Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing = 06.70 hours Option code G - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert = 06.70 hours Option code H - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert/spigot bearing = 06.70 hours

Europe/Rest of World - Defender Td5 12.53.89/35 - Flywheel and Fixings = 06.70 hours 12.53.89/36 - Flywheel /Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing = 06.70 hours 12.53.89/37 - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert = 06.70 hours 12.53.89/38 - Flywheel/Fixings/clutch cover/clutch driven plate/clutch fixings/release bearing/release arm/arm insert/spigot bearing = 06.70 hours

RECALL ACTION BULLETIN No: A/D211
Rover Group 2000

CKD - (Engine/transmission not yet installed in vehicle) DISCOVERY - 12.53.89/34 - 01.00 hour DEFENDER - 12.53.89/40 - 01.00 hour

NOTE: If CKD units are built up in vehicle and have been used in service one of the other above options may apply

ADDITIONAL INFORMATION: Normal warranty policies and procedures apply, it should be noted that this particular campaign will be subject to warranty audit.

The ‘K’ suffix parts CANNOT be used to repair or replace parts on a vehicle outside of the campaign VIN range, the usage of these parts will be rigorously monitored against VIN and total volume of cars repaired.

RECALL ACTION BULLETIN No: A/D211
Rover Group 2000