Massive clutch issues

1996 Discovery, 300TDI.

I have been struggling with this for the last 6 weekends and would appreciate any help/advice.

story so far.

The clutch on the Disco failed whilst driving and it was found to be the release fork had broken through at the pivot point, took it to a mate who suggested he also replaced the clutch as it was starting to show signs of wear. Got it all back together but couldn't get it to bleed. Replaced the slave cylinder, still not working, would bleed fine but then after a few minutes of driving would get air back into the system.

Found master cylinder was leaking under the reservoir replaced this, still no joy. Eventually found a small crack at the end of the clutch pipe by the damper. Replaced the pipe but still not working.

Finally found the new slave was overshooting its travel and letting air in past the seals. Reconditioned the old slave and now have the hydraulics bleed and air-free but still no clutch :( Pressing the pedal causes it to go straight to the floor and not return. If I connect a pressure bleeder to the system the clutch works correctly.

The piston moves fine in the slave.

Have found that when the guy refitted the clutch he didn't refit the clip that holds the piston rod to the fork, is this going to cause me a major problem?

If I move the clutch fork in the bell house it moves freely but there is no resistance, should there be? How does the slave cylinder get pushed back in?

My questions are:

Does this sound like a hydraulics issue? or a mechanical clutch issue? If a mechanical problem is there an easy way to get to the clutch without dropping the engine/ gearbox out completly?

I have several jacks but no engine hoist.

Taking the vehicle elsewhere is not an option.

Would appreciate any thoughts/suggestions

Ben

Reply to
Ben
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I'm not sure what you mean by "no clutch" but if the clutch pedal goes to the floor and won't return it looks like when you played with the master cylinder the length of the actuation rod changed, so the master cylinder piston is not returning far enough to allow the fluid to be pushed back into the reservoir.

AJH

Reply to
AJH

By "no clutch" I mean the clutch doesn't work. I press the pedal it goes to the floor and i can't change gear. The master on a 300TDi discovery doesn't appear to have any adjustment on it.

Ben

Reply to
Ben

This sound wrong, if I understand you correctly then the fork is not operating the clutch, so there is a problem in the re-assembly of the clutch parts. The fork is either not engaging on the release bearing, the release bearing has been left out, or the springs on the clutch plate are distorted.

Jeff

Reply to
Jeff

I can make the clutch operate by increasing the pressure in the system to the point that the slave piston travels out of the cylinder, but it won't operate under normal pedal pressure.

Sticking a screwdriver into the bellhousing and pressing the fork causes it to swivel back but it won't return, it needs to be manually pulled.

Thinking its a badly assembled clutch and i'm going to need to, somehow, get the gearbox off to have a look.

Thanks Ben

Reply to
Ben

I can make the clutch operate by increasing the pressure in the system to the point that the slave piston travels out of the cylinder, but it won't operate under normal pedal pressure.

Sticking a screwdriver into the bellhousing and pressing the fork causes it to swivel back but it won't return, it needs to be manually pulled.

Thinking its a badly assembled clutch and i'm going to need to, somehow, get the gearbox off to have a look.

Seems like a definite issue with the operating gubbins within the bellhousing. Afraid it's either engine out or gearbox off, nothing else for it. Might be worth comparing the new operating fork with the old to see if it's actually the correct item that's been fitted...... Badger.

Reply to
Badger

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