toady Posted May 16, 2008 Share Posted May 16, 2008 the story so far..... I have a 300 tdi discovery, she was sat up for approx 6 weeks whilst I done some work on her, got her through her mot, then took her on a round trip of 180 ish miles yesturday, not a problem at all she ran like the old disco i know and love!, but... jumped in her this morning put clutch in, and it felt a little strange like vibrations?? but she selected gears and off we went, went approx 50 yards and the pedal went to the floor and stayed there, no selection whatsoever, so turned her off selected first and set off in gear to get home, the pedal would come back if pulled up but stayed down once there, left the car for a couple of hours then went to have a look, and found that the pedal is now returning but will only go half way down, but still no gear selection. I was thinking either master or slave cylinder fault, but not sure what do you think?? Quote Link to comment Share on other sites More sharing options...
JimAttrill Posted May 16, 2008 Share Posted May 16, 2008 You will have to hope that it is a master or slave problem. Personally I think your clutch pushrod may have broken through the clutch fork, a not uncommon thing if the fork has not been reinforced. Quote Link to comment Share on other sites More sharing options...
toady Posted May 16, 2008 Author Share Posted May 16, 2008 You will have to hope that it is a master or slave problem. Personally I think your clutch pushrod may have broken through the clutch fork, a not uncommon thing if the fork has not been reinforced. how will i tell the difference, and if it is that, is it a big job / whats involved with that?? Quote Link to comment Share on other sites More sharing options...
jil6939 Posted May 16, 2008 Share Posted May 16, 2008 I think you will find Toady is correct in that i have always found ramdom clutch faults on a Disco to be the fork has punched through where it pivots on a ball. Prob best to fit a new clutch while it is all off. Quote Link to comment Share on other sites More sharing options...
JimAttrill Posted May 16, 2008 Share Posted May 16, 2008 I am not toady! Now to reply to toady: yes it is a biggish job, like all clutch jobs on a Land Rover. The gearboxes will have to be unbolted and moved back to give clearance to change the fork. Maybe you should do the whole clutch while you are there. Strengthened clutch forks can be made (one minute with a bit of metal and a welder) or you can buy them from Bearmach. I would have a look through the Technical Archive, there is bound to be an article about it in there. Quote Link to comment Share on other sites More sharing options...
freeagent Posted May 16, 2008 Share Posted May 16, 2008 Tech archieve contains a step-by-step guide to changing a 300Tdi disco clutch and fitting a strengthened clutch fork... I know this because it features my Disco... being worked on by Mr Henson. Quote Link to comment Share on other sites More sharing options...
nickm Posted May 16, 2008 Share Posted May 16, 2008 Toady whip the clutch slave cylinder out (13mm spanner) just undo the two bolts pull the cylinder out and check if the rod is still connected to the arm you should be able to see if its pushed thru not sure if its the same on a 300 but on the 200 if the arm goes back to far it wedges itself on the bell housing Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 16, 2008 Share Posted May 16, 2008 If the clutch pedal is rock solid, then the fork has punched through. Is there still fluid in the reservoir? Les. Quote Link to comment Share on other sites More sharing options...
toady Posted May 16, 2008 Author Share Posted May 16, 2008 there is still loads of fluid in, but the pedal just goes straight to the floor, even after i tried bleeding the slave it maid no difference, there is no resistance at all Quote Link to comment Share on other sites More sharing options...
sheltie50 Posted May 16, 2008 Share Posted May 16, 2008 Seen simillar fault on a Disco unfortunatly it was the clutch fork, I think its easier to move the engine forward as you might need to drop it to get to the upper bellhousing bolts, the answer will be in this forum its great. Good clutch kits used to be supplied with a replacement fork maybe still do and worth asking the question. Quote Link to comment Share on other sites More sharing options...
sheltie50 Posted May 16, 2008 Share Posted May 16, 2008 Just a thought, are you sure the master cylinder is working, I've seen a Disco with a sticking pedal, the master was goosed. Quote Link to comment Share on other sites More sharing options...
dooroy Posted May 17, 2008 Share Posted May 17, 2008 Just a thought, are you sure the master cylinder is working, I've seen a Disco with a sticking pedal, the master was goosed. When the fork failed ( pivot went through it ) on my 96 300 Tdi the pedal went solid - would only go down when bleed screw on slave was opened . I took out the engine as I had a way to lift - not too bad a job apart from a few bolts at the top of the bellhousing . I did the rear crank seal as well ; and I sorted out a few other niggles which were simple due to the great access . Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 17, 2008 Share Posted May 17, 2008 Clamp the flexi pipe with a pair of mole grips or similar (not too hard though). Then press the clutch pedal and if it still goes to the floor it'll be the master cylinder seals flipped over. Les. Quote Link to comment Share on other sites More sharing options...
toady Posted May 18, 2008 Author Share Posted May 18, 2008 ok went out last night, clamped the flexi pipe, presed the clutch down and lifted it up a few times with no change, still no resistance whatsoever, so is it safe to assume its the master????(fingers crossed!!) Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 18, 2008 Share Posted May 18, 2008 Yes, I would say so. Les. Quote Link to comment Share on other sites More sharing options...
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