740 clutch control arm problem

Make sure that the clutch control arm has not come adrift from it's pivot point.

All the best, Peter.

The only problem I've had with that is a worn assembly that allowed the piston to push completely out of the bore. When you say it's pushed through, do you mean the metal of the release arm has actually broken? If that's the case you'll have to replace it.

Perhaps I'm missing something, but it seems the obvious solution here is to get a new bushing, the dealer should be able to order it.

There isn't a bushing. The rod coming out of the slave cylinder seems to have worn a hole big enough so it goes right through the release arm. Sounds like it's time for a new arm (which would require transmission removal) or someone to patch up the existing arm (custom work which may end up costing the same as arm replacement).

Would a suitably thick and large enough diameter washer properly fixed onto the end of the actuator plunger not resolve this? Reading the posts below, it sounds like you need to investigate how the piston popped out, it should be securely held in place by a substantial internal circlip, you also should carefully clean the actuator piston, and it's bore, there is a long spring in there also which causes the actuator to maintain a very light pressure against the clutch release arm, after reassembly, fit the proper internal circlip, then refill and bleed the hydraulic circuit, I've had one of these badly and suddenly leak, giving a whole meaning to gear changing. This fix above won't look very neat, but, it should get you mobile again, and it's not like you drive around looking under the car all day:-)

Best wishes from blighty,

Ken Phillips