Tdi Defender diy clutch fix.

[LuigiV]

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!

[imgreg]

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.

[RossJ]

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

[LuigiV]

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/

[LuigiV]

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?

[RossJ]

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

[clivemd]

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

[LuigiV]

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.

[LuigiV]

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.

[clivemd]

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,

[RossJ]

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

[Sam vd Merwe]

If i am alone i gravity feed it. Then i close up and pump it. 80 persent of the time it works

[GaryFrank]

Where are you based

[LuigiV]

Where are you based

I'm in Tulbagh, W-Cape.

[LuigiV]

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.

[GaryFrank]

I'm in Tulbagh, W-Cape.

Sorry.... too far for me