Clutch Adjustment on a Series Land Rover
The Series I and early Series II's have a clutch mechanism which requires adjustment manually. Later Series models have a hydrostatic mechanism which is self adjusting once it has been correctly set initially. The photo above illustrates the earlier mechanism; the later system has a bracket which is open on one side and there is no pushrod return spring.
Before setting up the clutch mechanism, the bottom of the clutch pedal pad should be set to 158mm above the floor (remove carpet etc) on the early mechanisms and 140mm on the hydrostatic mechanism. This is done under the bonnet by adjusting the bolt on the back of the clutch pedal housing. The freeplay in the clutch master cylinder pushrod should be set to 1.5mm (both mechanisms) by adjusting the locknuts on the clutch master cylinder pushrod shaft. As a check, there should now be about 8mm free movement at the pedal pad. Having set the clutch pedal it is now time to set the clutch adjustment mechanism itself.
Slacken the locknut at the bottom of the clutch slave cylinder then turn the slave cyinder pushrod until the free play at the clutch pedal increases from the 8mm set earlier to 38mm. Then tighten the locknut.
As the clutch plate becoame worn and other wear occurs in the actuating mechanism it is necessary to check and repeat this procedure to ensure that the clutch palte is fully engaging/disengaging as required.
Unlike the earlier system, the slave cylinder pushrod has a nut at the top of the thread (call this nut 'A'), it is important that this nut be tigthened fully up against the end of the thread as it is an important measurement reference. The nut below this, which actually locks the pushrod in position should now be loosened and the pushrod rotated until the distance between the bottom surface of nut 'A' and the mating surface of the slave cylinder and its mounting bracket is 2.5in (73.4mm). You really need calipers to get this accurate (call it distance 'B'). The locknut for the pushrod should then be tightened. Once this is done then the gradual clutch plate wear should be accommodated automatically. Needless to say, the clutch mechanism should be already set corrctly so it should only be necessary to confirm that distance 'B' is infact 2.5in then no further work is necessary.
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