Disco 2 Clutch pedal travel is not right.

Well, Found this in the clutch housing, when I pulled the slave out.



And who ever designed the way the crossmembers are attached should be shot!.

Cheers

So finally got the tbox and gbox off,

Found the following. Oil leak in bell housing, will see tomorrow when clutch is removed but could be sump gasket failed.
Also a lot more fluff like previously.
Noticed release bearing plastic tag appears to have melted!!!

Apart from that cannot see any reason the clutch has decided to only work in the lower section of pedal stroke.

1 more

Thanks for the updates

neilly said:

So finally got the tbox and gbox off,
View attachment 145292 View attachment 145292 View attachment 145293 View attachment 145294
Found the following. Oil leak in bell housing, will see tomorrow when clutch is removed but could be sump gasket failed.
Also a lot more fluff like previously.
Noticed release bearing plastic tag appears to have melted!!!

Apart from that cannot see any reason the clutch has decided to only work in the lower section of pedal stroke.

Click to expand...

I'd say that there might just be a bit missing from that release bearing mate:-

brian47 said:

I'd say that there might just be a bit missing from that release bearing mate:-

View attachment 145296 View attachment 145297

Click to expand...

Cheers Brian, TBH have not checked it against the replacement bearing as it fought every inch of the way today and I have given up until the sun rises Tomorrow. But will check when I get back out to the shed.

Cheers

@brian47

Well, sad to say checked the new one against the old one and they are the same....release bearing came with a Valeo kit. Still at a loss.

Cheers

I've not seen a thrust bearing for years but the one on yours does not look right surely? There is no thrust material left and that would cut into the cover fingers.
Yet the replacement is the same
I think that would explain the pedal too .

Flossie said:

I've not seen a thrust bearing for years but the one on yours does not look right surely? There is no thrust material left and that would cut into the cover fingers.
Yet the replacement is the same

Click to expand...

I've not seen one for this gearbox either, but I'd agree that there should be something else there surely - a metal bearing face or a carbon ring type thingy (sorry if I'm getting technical...). There seems to be more black fluff at the end of your bellhousing too.

Edit to add...Just had a look at various suppliers sites, and they all show a bearing surface in the centre where you have fresh air. I wonder what the bearing itself is? If it were a roller or ball bearing I would have thought you'd have seen at least a few left in the housing, even if most of them had fallen out of the drain hole.

Well, I spoke to supplier emailed them , chased them and he says it is wrong and is missing the ctr section......

He sent me a replacement which has arrived, This has the revolving inner section, but the outer edge does not revolve. ON the original ones supplied the outer ring did revolve and runs like a bearing. I will use the new one , maybe there is a duff batch around, or it is a new design Valeo are using, who knows.

Thanks, now just got to get the damn thing back together.

Cheers