Results 1 to 16 of 16
  1. #1
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Tdi Defender diy clutch fix.

    Last week my clutch peddle started squeaking and yesterday suddenly there was nothing, peddle stayed on the floor. Currently the peddle goes halfway to the floor, not further, and the spring will return it.

    I have to fix this myself, 1) I don't have the finances to have it done. 2) I have time. 3) I will learn a lot about my car.

    When asking around about where to start (I'm leaning to removing the peddle box first), somebody mentioned the thrust bearing fork which is prone to failing in Defenders. Is there a surefire way to figure out what's wrong before starting repairs? Any advice and suggestions will be appreciated, thanks!
    Land Rover Defender 90 Tdi

  2. #2
    Join Date
    Feb 2011
    Location
    Port Elizabeth
    Age
    59
    Posts
    2,315
    Thanked: 658

    Default Re: Tdi Defender diy clutch fix.

    This is what we do to make sure it can not break again.
    I have a spare one, nothing wrong.
    If you open your box and see its the fork let me know i will post my spare one to you, no charge.
    Attached Images Attached Images  
    Defender Kalahari
    Series 3 SWB
    Series 1 De Luxe Cab Pickup
    Series 1 Station Wagon 88''

  3. The Following 3 Users Say Thank You to imgreg For This Useful Post:


  4. #3
    Join Date
    May 2009
    Location
    Pretoria
    Age
    57
    Posts
    3,341
    Thanked: 186

    Default Re: Tdi Defender diy clutch fix.

    that doesn't sound like a hole in the clutch fork

    the halfway down description is the confusing bit

    there is a rod linkage about 3/4 way up the brake pedal that conects to the clutch master cylinder - which itself is bolted to the firewall

    so you won't see the rod operating

    i would loosen those two bolts and see if pedal depth follows it

  5. #4
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by imgreg View Post
    This is what we do to make sure it can not break again.
    I have a spare one, nothing wrong.
    If you open your box and see its the fork let me know i will post my spare one to you, no charge.
    Thanks for the offer!will definately take you up when the time comes. When I eliminated any other possibilities, I will carefully follow the instructions as layed out here: https://forums.lr4x4.com/topic/5009-...r-clutch-fork/
    Land Rover Defender 90 Tdi

  6. #5
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by RossJ View Post
    that doesn't sound like a hole in the clutch fork

    the halfway down description is the confusing bit

    there is a rod linkage about 3/4 way up the brake pedal that conects to the clutch master cylinder - which itself is bolted to the firewall

    so you won't see the rod operating

    i would loosen those two bolts and see if pedal depth follows it
    Thanks for the reply. The first time it went, the peddle did go to the floor board, I then pulled it up by hand. When I tried to push it down again it would only go halfway.

    I'm not clear on which two bolts. The clutch peddle bits and the master cylinder is housed in a "peddle box", this box is bolted onto the firewall from the inside with six bolts, are you refering to two of those bolts?
    Land Rover Defender 90 Tdi

  7. #6
    Join Date
    May 2009
    Location
    Pretoria
    Age
    57
    Posts
    3,341
    Thanked: 186

    Default Re: Tdi Defender diy clutch fix.

    i have a disco 1 so didn't think it would be that different

    the web pics i see looks like it's on the firewall inside the engine bay ?

    apologies

  8. #7
    Join Date
    Mar 2015
    Location
    New Germany
    Age
    50
    Posts
    1,454
    Thanked: 838

    Default Re: Tdi Defender diy clutch fix.

    When you pressed the clutch was there there the normal resistance and then poof no resistance and straight to the floor,
    if so probably push rod has pushed through the clutch peddle, before you remove anything on brake peddle area I would unbolt slave and see in there
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  9. The Following User Says Thank You to clivemd For This Useful Post:


  10. #8
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by RossJ View Post
    i have a disco 1 so didn't think it would be that different

    the web pics i see looks like it's on the firewall inside the engine bay ?

    apologies
    I got these pics from Google. The first pic shows the 6 bolts where they're removed from the inside of the fire wall. The second one shows the complete peddle box assembly with the master cylinder, and the third image shows where the plunger goes into the master cylinder, accesable when you remove a little plate...this is from inside the engine bay.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	LR_peddle_1.jpg 
Views:	32 
Size:	39.4 KB 
ID:	604081   Click image for larger version. 

Name:	LR_peddle_2.jpg 
Views:	30 
Size:	56.7 KB 
ID:	604082   Click image for larger version. 

Name:	LR_peddle_3.jpg 
Views:	33 
Size:	115.5 KB 
ID:	604083  
    Land Rover Defender 90 Tdi

  11. #9
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    I have difficulty to decide if I should go for the clutch fork or for the master cylinder. Looking at the master cylinder, there's no hydraulic fluid to be seen leaking anywhere down to the slave, also the plunger on the master looks like it's doing it's full stroke...I know I said earlier that the peddle only goes halfway, but it's further than that, it's difficult to judge because there's so little pressure on the peddle...which will make sense if there's a hole in the clutch fork.

    Right now I'm more inclined to think that the problem is with the clutch fork.
    Land Rover Defender 90 Tdi

  12. #10
    Join Date
    Mar 2015
    Location
    New Germany
    Age
    50
    Posts
    1,454
    Thanked: 838

    Default Re: Tdi Defender diy clutch fix.

    Happened to my 300TDi driving in town on way home clutch fine, next robot clutch in and poof straight to floor, clutch for gone, drove home crash changing,
    1995 300TDi Defender with VGT Turbo (stolen by my son now )
    2002 Defender with LS1 MS3 ECU, 4L80e, LT230 1.222, Lockers and HD CW&P, 35" with 4" Lift
    2005 Defender TD5

  13. #11
    Join Date
    May 2009
    Location
    Pretoria
    Age
    57
    Posts
    3,341
    Thanked: 186

    Default Re: Tdi Defender diy clutch fix.

    clive's suggestions makes sense

    needs 2 people though
    as top person presses clutch undo bleed nipple on slave

    should squirt out

    keep clutch pedal down and tighten bleed screw otherwise you drawing air in

  14. #12
    Join Date
    Mar 2014
    Location
    Brakpan
    Age
    51
    Posts
    3,441
    Thanked: 294

    Default Re: Tdi Defender diy clutch fix.

    If i am alone i gravity feed it. Then i close up and pump it. 80 persent of the time it works
    Four wheels move the body,
    Landys move the soul.
    0735236742
    Current: Discovery 2 td5.
    Next landy, D3 V8 HSE Previous one.D1 v8i D1 300 TDi donkey, D1 V8 Fuel THIEF!!! freelander 1, biggest pos known to man,

  15. #13
    Join Date
    Apr 2013
    Location
    cape Town - 0825509200 / 0624206806
    Age
    61
    Posts
    2,454
    Thanked: 505

    Default Re: Tdi Defender diy clutch fix.

    Where are you based

  16. #14
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by GaryFrank View Post
    Where are you based
    I'm in Tulbagh, W-Cape.
    Land Rover Defender 90 Tdi

  17. #15
    Join Date
    Feb 2007
    Location
    Tulbagh
    Age
    57
    Posts
    141
    Thanked: 7

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by clivemd View Post
    When you pressed the clutch was there there the normal resistance and then poof no resistance and straight to the floor,
    if so probably push rod has pushed through the clutch peddle, before you remove anything on brake peddle area I would unbolt slave and see in there

    Thanks, I'll do that. Hopefully I get some time tomorrow.
    Land Rover Defender 90 Tdi

  18. #16
    Join Date
    Apr 2013
    Location
    cape Town - 0825509200 / 0624206806
    Age
    61
    Posts
    2,454
    Thanked: 505

    Default Re: Tdi Defender diy clutch fix.

    Quote Originally Posted by LuigiV View Post
    I'm in Tulbagh, W-Cape.
    Sorry.... too far for me

  19. The Following User Says Thank You to GaryFrank For This Useful Post:


Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •