Clutch Issue

Hello all - hoping someone can help! My clutch pedal went flat and wouldn't come up. Clutch fluid was leaking and wouldn't stay full.The mechanic came and changed the clutch slave. Now the fluid stays and he said the clutch master cylendar is fine but the clutch pedal is rock hard. Any idea why?

has it been bled properly?

Clutch fork failed most likely. Cheap part (get a reinforced one) but gearbox has to be removed to replace it so you need to weigh up if you're goning to do full kit at the same time

Mike at Britannica Resorations in Canada does a good kit to uprate the clutch fork. Unfortunately it's a common failure point.

If clutch fork failure, HD/reinforced forks and thrust bearing kits are readily available in the UK

raisingveg said:

has it been bled properly?

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Yep three times. Also thought something was up with the clutch pedal but that was checked. My fear is the clutch and/clutch fork but it sounds like that's it.

JPH said:

Yep three times. Also thought something was up with the clutch pedal but that was checked. My fear is the clutch and/clutch fork but it sounds like that's it.

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Fairly common I'm afraid, not a hard job to sort out though. Either buy a reinforced one or buy a standard one and weld some supports on it. I had it happen twice on previous land rovers. Second time around I made my own

Marmaduke said:

Fairly common I'm afraid, not a hard job to sort out though. Either buy a reinforced one or buy a standard one and weld some supports on it. I had it happen twice on previous land rovers. Second time around I made my own

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Wow thats crazy twice?!!!?! Well while it's open I'm getting a new clutch as well. For the $1000 labor I may as well. Thanks for the advice and reply! I'm new to the Defender world but I love them. An older defender is something I've always wanted!!

JPH said:

Wow thats crazy twice?!!!?! Well while it's open I'm getting a new clutch as well. For the $1000 labor I may as well. Thanks for the advice and reply! I'm new to the Defender world but I love them. An older defender is something I've always wanted!!

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Yeah alas my new 'reinforced' one failed within a month or so So I made my own

Hello all - so I received the clutch and the mechanic tried to put it in and it doesn't appear to fit. Does anyone know if there are different clutches for the 300tdi engine? Here are pics of the old clutch.

JPH said:

Hello all - so I received the clutch and the mechanic tried to put it in and it doesn't appear to fit. Does anyone know if there are different clutches for the 300tdi engine? Here are pics of the old clutch.

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No, but there is a front and a back....

Thanks. I was doing a little research and found this. The original clutch is top left, one I received is on the right. The bottom left comes up as one for a 94 defender 300tdi.

JPH said:

Thanks. I was doing a little research and found this. The original clutch is top left, one I received is on the right. The bottom left comes up as one for a 94 defender 300tdi.

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in what way doesnt it fit

jamesmartin said:

in what way doesnt it fit

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When the mechanic was putting the transmission back in place it wouldn't fit

JPH said:

When the mechanic was putting the transmission back in place it wouldn't fit

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that might be more down to him, presumably her tried fitting the clutch plate on the gear box shaft splines first

So what we found is that the thickness of the spline shaft is different. The new one is a little thicker than the original. So it's not only the number of springs but the spline shaft.

JPH said:

So what we found is that the thickness of the spline shaft is different. The new one is a little thicker than the original. So it's not only the number of springs but the spline shaft.

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number of springs doesnt mean anything ut theres only 2 spline diameters v8 19mm and diesel 22mm

Ahhh yes!!! Thank you all for ur help!

Hey all - clutch is replaced. Now the problem is that when I accelerate it feels the handbrake is on and there is a loud hallow noise coming from under the hood. The engine wants to go but something is holding it back. Any ideas?

JPH said:

Hey all - clutch is replaced. Now the problem is that when I accelerate it feels the handbrake is on and there is a loud hallow noise coming from under the hood. The engine wants to go but something is holding it back. Any ideas?

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pulled a turbo hose off?