Urgent Help Please!!

Hi all,

I've just changed the master cylinder in my 1998 300tdi defender 90. When i put the pedal box back in, the pedal looks way too far towards the bulkhead, this is prooved as the assistance spring wont go back on where the pedal is and the peadl wont come back any further. Any ideas? Secondly after bleeding system and with a constant flow of air free fluid, there is about half free play and half resistance?? I am Stumped any advice would be great.

Thanks Oli

just answered you first post

The spring is a challange to get on at the best of times.
Have you measured and adjusted the pedal height from the floor ???
Bet you will find this is out. Also did you replace the slave cylinder ??
Best to change as a pair since the master cylinder will be exerting a higher pressure now so the slave will fail, usually pretty quickly ?? did you use Lucas parts ?? dont rate the cheaper ones.
What condition is the flexi hose in ?? i change this at the same time as the master and slave cylinder.

The pedal should be 140mm from the bottom of the pedal to the floor with out mats

Andymcd, when you talk about height from the floor, do you mean from the bulkhead or from the footwell? I changed the slave a few weeks ago, both with lucas parts, the flexi hose looks in good condition but maybe i should have changed that too?

Many thanks for your replys

Straight (vertically) down from the pedal to the floor pan

It is at 120mm from the floor, any ideas on how to bring it up? Thanks very much for your help.

Taken from your other thread

jamesmartin said:

the rod that goes from pedal to cylinder is adjustable you need 13mm or 1/2 inch ring spanner with end cut enough to go over rod ,if you go too far it can stop oil returning to res allowing clutch to remain pressed and slippage

Click to expand...

As above. It is adjusted by moving the nut and lock nut on the thread of the master cylinder, keep doing this till you get 140mm and the pedal will feel a lot better.