Clutch pedal broke - any guesses before I investigate?

I was pulling out of my drive on Friday and noticed that the clutch pedal on me 300TDi was feeling a bit on the stiff side - a bit like I was pressing the brake pedal with my left foot. Being in a rush and not thinking I stamped on it a bit harder and with a *crack* it went straight to the floor. Now there's no pedal at all.

So, anyone want to take a guess as to what it might be that's broke? I'm going to have a look when I've finished my coffee...

Cutch fork, gearbox out job.

Wot he said^^^^^.

Clutch fork worn through.:doh:

what they said ^^^^^^

link for a 110 defender but you get the idea http://forums.lr4x4.com/index.php?showtopic=5010

defo what they said

I don't know if this is correct forum etiquette sorry - jumping onto someone elses post but this is only my second go at this and the problem above sounds like the one that I am dealing with today. Last night the clutch pedal went hard, no warning, just started it up outside the shop and it was rock solid, cant put it in gear or depress it all. I got towed home by a lovely man from the RAC and he told me that he suspects the clutch arm had pierced something or snapped and that is was a common fault on these (I have a 300TDI). I have called my local garage who service my car and do all other repairs and told them what has happened and they want £400 + VAT for the job as the gearbox has to come out. Does this sound reasonable? and before anyone says give it a go yourself I am a single woman owner so putting petrol, water and checking the oil levels is about as far as my car knowledge goes I'm afraid.

My neighbour is a mechanic in a large Beema dealership, could he do it road outside? would you trust someone not used to doing Discos? if yes what would you do it for as a weekend sideline job - just wondering what to offer him?

I am not having much luck this month, exhaust fell off two weeks ago, rear electric windows just stopped working a few days ago and now this, so if it is the £400 option then my £1500 Discovery is starting to worry me.

Thanks very much in anticipation.

How far from Cardiff are you domino? You could ring Len at Autocraft 029 20668791 or HBH in Caerphilly on 029 20882368 for some alternative quotes...and don't forget,depending on what level of RAC membership you have, you may be able to get the RAC to get it to whoever repairs it.

domino666 said:

....(I have a 300TDI)...putting petrol, water and checking the oil levels is about as far as my car knowledge goes I'm afraid.....

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I hope you put diesel in it, not petrol...

Now then Mr Martin, I may be female but I did use the black pump to put diesel in my car!
I am in Caerphilly so have heard alot about HBH, very mixed stuff tbh, I thought they were very expensive so didn't bother calling them for this problem as I think the majority of the cost will be labour and I may be wrong but their hourly rate is quite high, I did price them once for a service and they were double what I pay in Commercial Garage, Abertridwr. Not heard of Autocraft so will give them a call now and explain the prob and see what horrific price I get from there, although nothing could be worse that £400 right now I think.
What do you think about my neighbour, my garage told me it is around 6 hours labour, would you do it for £150 ish?

Yes, I have heard that HBH are expensive Domino. The only trouble with your neighbour doing it on the road side is that the gear box is very heavy and difficult to get out safely. You are meant to use a hoist pushed in through the passenger door to support the box with a sling while you undo everything. Some people say its easier to get the engine out, but that would need a hoist as well.

domino666 said:

Now then Mr Martin, I may be female but I did use the black pump to put diesel in my car!
I am in Caerphilly so have heard alot about HBH, very mixed stuff tbh, I thought they were very expensive so didn't bother calling them for this problem as I think the majority of the cost will be labour and I may be wrong but their hourly rate is quite high, I did price them once for a service and they were double what I pay in Commercial Garage, Abertridwr. Not heard of Autocraft so will give them a call now and explain the prob and see what horrific price I get from there, although nothing could be worse that £400 right now I think.
What do you think about my neighbour, my garage told me it is around 6 hours labour, would you do it for £150 ish?

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Hi Domino, this almost certainly will be the clutch fork pierced. The fork on it's own is about £12 for an HD one, there are a few little bits and pieces which are worth changing at the same time which would total less than £20 so about £30 for the bits.

Assuming your clutch operated quietly and correctly beforehand I would and did leave it alone when I did this work at home on my wife's Disco.

It's not too hard to do, but would suggest it needs two pairs of hands to do at home.

I did it using two trolley jacks and separating the bellhousing from the engine about 8-10inches only. It's the first and only time I've done this job but by working slowly and methodically all went well and "Dora" runs like new again.

If you decide to have it done by next door neighbour I would say it's at least a day's job, if not weekend, so needs to be £200-250 labour.

If you/your mechanic needs to know more pm me.

Cheers
Dave

thebiglad said:

there are a few little bits and pieces which are worth changing at the same time which would total less than £20 so about £30 for the bits.
Cheers
Dave

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wot "few little bits and pieces£?

The Mad Hat Man said:

What "few little bits and pieces£?

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Release bearing, slipper pads, plastic clip, pushrod, pushrod clip - probably comes to about £15 in total plus some copper grease.

There is a drawing on the RAVE CD for the adaptor plate to remove the gearbox/transfer box, but it must be touch and go whether to lift the engine out?

I've had our V8 out for a rebuild (Disco 2) and looking under the vehicle at the tranmission, I'd probably go for the engine out if I had to do the clutch now.

The combined unit is dammed heavy and no joke if it fell on you under the vehicle!

The cross-member screws are nearly always going to be rusted solid and snap off, which is extra hassle (I had to drill out and re-tap mine) plus there's the interior trim, levers etc etc.

Peter

listerdiesel said:

The cross-member screws are nearly always going to be rusted solid and snap off, which is extra hassle (I had to drill out and re-tap mine) plus there's the interior trim, levers etc etc.

Peter

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On the TDi's you don't need to remove the crossmember, you actually rest the gearbox/transbox assembly on it to do the work.

Well just wanted to say thanks guys, neighbour and one of his colleagues are going to do it in my garage starting tomorrow and finishing Friday after their day jobs. £150 labour plus costs of parts so I am extremely relieved, passed on all of your comments and they are coming prepared for the weight of the gearbox so I have every finger and toe crossed that it will all be ok.

i did mine with no previous experience following this link
Discovery clutch change - LR4x4 - The Land Rover Forum

i did quite well for an idiot.

gotoneatlast said:

i did mine with no previous experience following this link
Discovery clutch change - LR4x4 - The Land Rover Forum

i did quite well for an idiot.

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That's the one I used to do mine - first class set of instructions !!

Btw, you'll need two trolley jacks

Dave