300Tdi Clutch problem

[Ben1982]

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 completly bleed, air was being introduced on the upstroke of the clutch pedal.

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 fit 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, or is drawn in by the return action of the master?

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 isn't going to be very easy and would prefer to do the work myself.

Would appreciate any thoughts/suggestions

Ben

[cipx2]

he didn't fit the clip that holds the piston rod to the fork

^^^^^^^ this is your #1 problem at the moment. No need to remove engine/gearbox. Remove clutch slave cylinder and try something like FridgeFreezer suggest here http://forums.lr4x4.com/index.php?showtopic=13246 (mind the 2nd picture is from a V8) or "invent" your own method, you'll come up with something.

I suggest you do this 1st and report back on what the symptoms are with that plastic holder fitted if it's still not working properly.

[Paul2A]

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, or is drawn in by the return action of the master?

Hello Ben, the fork will pull out towards you quite freely, however it should not move all the way in, when pushing it in if it's getting close to hitting the casting you have problems.

Have you tried to gently waggle the fork up and down? is there any movement?

[Les Henson]

If the fork clip isn't fitted, then maybe the second clip that holds the opposite end of the fork to the thrust bearing is missing too. If the thrust bearing end of the fork comes away from it for even a brief moment and the thrust bearing turns - it might be possible that the fork then engages on the back of the bearing instead - thus reducing the clutch action. The pedal would travel further before resistance is felt and may not fully disengage the clutch. If the slave rod had come out of the fork, then it will either press against the back of the bellhousing and not operate the clutch, or move off to one side and allow the slave piston to move too far out. I would expect the slave piston to come right out of the body and fall into the bell housing - dumping the fluid inside it at the same time.

Les.

[Paul2A]

Pretty much what I was thinking, if the fork has come off the release bearing there should be a bit of movement 'up and down' if ya like.

I find it is a good idea to use a few elastic bands around the fork and bearing to make sure it sits tight whilst being offered up.

[Ben1982]

Thanks for everyones suggestions,

I have tried to reattach the clip but can't get it in, even using the suggested tool.

I also have a fair bit of movement up and down on the clutch fork, I take it this isn't good?

The fork will move all the way to the front of the bellhousing, but only half way to the back is this normal?

Looks like removing the gear box/engine to have a proper look. What would be the safest/best way to do this?

Been told I can, remove engine, tip engine back with it still in place or remove the gearbox. Any others?

Thanks for everyones help

Ben