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partydave

Discovery 2 TD5 clutch adjusment

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Hi guys. 

I need some help please, at my wits end with this bloody thing.

Is there any way to adjust the bite point of a 2000 Discovery 2 TD5 clutch?

I had the gearbox and transfer case rebuilt about 9 months ago. When the indy dropped the box, he managed to bend the friction plate, all I heard was money flushing down the drain. Fast forward a couple of months and 2 new indies, the gearbox and a new friction plate is in and I am finally able to drive the Disco, albeit with some effort. When the motor is running, it is impossible to select first and reverse, second is tough, but possible and the rest relatively easy. Able to engage all gears when motor is off. Originally, I was unable to select any gears when the motor was running so they lightly skimmed the flywheel and tested the clutch assembly on the test bench and confirmed everything to be working. The previous indy did remove the master cylinder for some reason.

What I've noticed is that when I depress the clutch when Disco is in first, it still rolls forward. The pedal is about 150mm below the brake pedal. The bite point is also extremely low. 

Is there actually a way to adjust the bite point on a Disco 2? Fairly certain it's bled properly via reverse bleeding.

 

Thank you for reading my long post

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I think you want to find a new garage that knows what they are doing. When you say "dropped the box" what actually happened - do you know / did they admit it? Do you mean they didn't pull it out of the clutch when they took the box out of the vehicle, or they literally dropped it?

It sounds like the possibilities are either some damage to something that hasn't been identified (input shaft bent) or there are still defects in the system (the Td5 flywheel is a known weak point and they were all replaced under a recall at some point in their life).

It could be just hydraulics/air in the system but it could be something else. Really hard to say without seeing it when you know 'something' has happened but are not sure what.

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Hi Dave, As it's a hydraulic clutch there is no adjustment -unlike a cable operated one.

Griff

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3 hours ago, bear said:

Hi Dave, As it's a hydraulic clutch there is no adjustment -unlike a cable operated one.

Griff

Thanks Griff. I was hoping there would be a way to adjust it. The pedal isn't level with the brake pedal

4 hours ago, BogMonster said:

I think you want to find a new garage that knows what they are doing. When you say "dropped the box" what actually happened - do you know / did they admit it? Do you mean they didn't pull it out of the clutch when they took the box out of the vehicle, or they literally dropped it?

It sounds like the possibilities are either some damage to something that hasn't been identified (input shaft bent) or there are still defects in the system (the Td5 flywheel is a known weak point and they were all replaced under a recall at some point in their life).

It could be just hydraulics/air in the system but it could be something else. Really hard to say without seeing it when you know 'something' has happened but are not sure what.

3 different garage, last one finally managed to get it drive-able.

First garage let the front of the box drop while removing, input shaft grabbed the friction plate and bent the whole thing. Input shaft was replaced with rebuild thankfully.

I'm reading a lot of reports that there could still be air in the system, but I'm sure it was bled thoroughly.

Could a failing master cylinder cause the low bite point and 1st selection issues perhaps?

Could an old pressure plate be to blame? (not replaced, just friction plate)

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18 hours ago, partydave said:

Could an old pressure plate be to blame? (not replaced, just friction plate)

im amazed that given the work involved for taking the box out that just the friction plate was changed

 

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I have a dim recollection that something odd can happen with the master cylinder seals, they somehow turn inside out or something weird, very unusual, so a master cylinder problem is not to be ruled out. We had one years and years ago at the garage with a problem something like that, nobody had touched the master cylinder so it was largely ignored, and it turned out that something had happened to the seal inside the cylinder.

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On 1/31/2019 at 4:15 PM, partydave said:

 The pedal isn't level with the brake pedal

The pedal position is adjusted from inside the cabin.

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