Rover DEFENDER 300Tdi, Workshop Manual

Page: 147 / 450

CLUTCH
1 OVERHAUL
MASTER CYLINDER - OVERHAUL
Service repair no - 33.20.07
Dismantle
1. Remove master cylinder from vehicle See
Repair, Master cylinder .
2. Remove circlip.
3. Withdraw push-rod and retaining washer.
4. Withdraw the piston assembly. If necessary,
apply a low air pressure to outlet port to expel
piston.
5. Prise locking prong of spring retainer clear of
piston shoulder and withdraw piston.
6. Withdraw piston seal.
7. Compress spring and position valve stem to
align with larger hole in spring retainer.
8. Withdraw spring and retainer.
9. Withdraw valve spacer and spring washer from
valve stem.
10. Remove valve seal.
Inspection
11. Clean all components in new hydraulic fluid and
allow to dry.
12. Examine cylinder bore and piston, ensure that
they are smooth to touch with no corrosion,
score marks or ridges. If there is any doubt, fit
new components.
13. The seals should be renewed with seals from
master cylinder overhaul kit.
Assemble
14. Smear seals with suitable rubber grease and
remaining internal items with new hydraulic fluid.
15. Fit valve seal, flat side first, on end of valve
stem.
16. Place bowed washer, domed side first, over
small end of valve stem, see J6281.
17. Fit spacer to valve, legs first.