200TDi into 2A, having some clutch problems

Hi guys, I'm carrying out a 200 TDi conversion and would be greatful if anyone could offer any advice, I've fitted my original 2A Diesel clutch cover plate along with a new 2A Diesel driven plate on to the standard discovery flywheel but the problem I'm having is i dont seen to have enough travel in the release mechanism to make the cluch release, the slave cylinder is almost at the end of its travel before the pedal is pressed, if the slave cylinder was adjucted any further out it would almost touch where the prop shaft comes out the box when the pedal is pressed. Theres a pic of clutch and my gearbox below, as you can see its the early? style box with the enclosed release bearing set up, I cant help wondering if the shaft inside this has been fitted a few splines out or whether the conversion cant be done with this style gearbox?


Cheers

I recall others having this issue.
One of the businesses that does conversion kits for this might even do a special spacer for the slave cyl.
So long as the release arm has enough reach to disconnect the clutch drive then you'll able to have a spacer made, or a new longer dowel for the slave cyl.

Try measuring the offset between the face of the flywheel and the flywheel housing to bellhousing face, on both the Tdi and your old 2.25 engine, to see if there is a difference. I had no problems with the clutch when installing a 200Tdi onto a SIII gearbox. I used a SIII clutch plate and the 200Tdi pressure plate. If I remember correctly on a IIA there is a tube which transmits torque to the clutch release mechanism. Perhaps making a new tube with different positioning of the bolt holes would solve the problem.

i made a 1/4" thick spacer and welded it to the pressure plate

i am just about to fit a 200tdi with a s111 box in to a s1 any help would be great. wat has the best idea ,welding a spacer sounds the best way to go .

fenby1976 said:

Try measuring the offset between the face of the flywheel and the flywheel housing to bellhousing face, on both the Tdi and your old 2.25 engine, to see if there is a difference. I had no problems with the clutch when installing a 200Tdi onto a SIII gearbox. I used a SIII clutch plate and the 200Tdi pressure plate. If I remember correctly on a IIA there is a tube which transmits torque to the clutch release mechanism. Perhaps making a new tube with different positioning of the bolt holes would solve the problem.

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hope you dont mind me saying but in your pics i think i recognise your series 3 ambulance do you fit kitchens or do tiling by any chance as i remember someone turning up on one of my old jobs in one of those