Clutch Problem

Landlover99 · Sep 24, 2018

Hi all,
Got a problem with the clutch on my Defender 110. The first half of the pedal's travel is only resisted by the pedal return spring. Only when over half-way down do I feel the heavy resistance of the hydraulic valve present itself, so the clutch only becomes fully disengaged at about one inch above the floor. So it's very hard pulling away smoothly from a standstill as the clutch goes from fully disengaged to fully engaged over such a tiny range of movement so close to the floor. It's something that's just gradually got worse and worse over time.
Any suggestions as to what might be causing this problem would be welcome; many thanks.

Kwakerman · Sep 24, 2018

Landlover99 said:
Hi all,
Got a problem with the clutch on my Defender 110. The first half of the pedal's travel is only resisted by the pedal return spring. Only when over half-way down do I feel the heavy resistance of the hydraulic valve present itself, so the clutch only becomes fully disengaged at about one inch above the floor. So it's very hard pulling away smoothly from a standstill as the clutch goes from fully disengaged to fully engaged over such a tiny range of movement so close to the floor. It's something that's just gradually got worse and worse over time.
Any suggestions as to what might be causing this problem would be welcome; many thanks.

Assume you have done the obvious and checked the fluid level?

Landlover99 · Sep 24, 2018

Yeah, it is fine. (assuming it's the same header pod as the braking system uses)

tottot · Sep 24, 2018

What year ?

Kwakerman · Sep 24, 2018

Landlover99 said:
Yeah, it is fine. (assuming it's the same header pod as the braking system uses)

Er no its not normally! Clutch master cylinder reservoir is normally on the bulkhead to the right (as you look at it) of the brake servo.

Kwakerman · Sep 24, 2018

You got the silver cap in the middle of the piccy (could also be white plastic)?

Landlover99 · Sep 24, 2018

tottot said:
What year ?

2003

Landlover99 · Sep 24, 2018

Kwakerman said:
You got the silver cap in the middle of the piccy (could also be white plastic)?

I can't resolve that image here for some reason.

Landlover99 · Sep 24, 2018

Kwakerman said:
Er no its not normally! Clutch master cylinder reservoir is normally on the bulkhead to the right (as you look at it) of the brake servo.

I'll have to check that out in the morning 'cos it's well dark here now .

Kwakerman · Sep 24, 2018

Landlover99 said:
I can't resolve that image here for some reason.

Should just be a normal pdf

Al2O3 · Sep 24, 2018

Kwakerman said:
Should just be a normal pdf

Opened fine for me. Bit grubby that engine bay mind, just saying

Landlover99 · Sep 24, 2018

Kwakerman said:
Should just be a normal pdf

I can see it now. I don't remember anything like that. On mine there's a white plastic reservoir with a white plastic cap for the fluid immediately in front of the brake servo and directly above the master cylinder. So mine's obviously not the same model as yours, then. I gotta hit the hay now as I want to spend all day checking it over tomorrow. If you or anyone else knows what could be causing the low pedal issue outlined in post #1 then I'll look forward to reading your thoughts in the morning. Night-night!

jamesmartin · Sep 24, 2018

Landlover99 said:
I can see it now. I don't remember anything like that. On mine there's a white plastic reservoir with a white plastic cap for the fluid immediately in front of the brake servo and directly above the master cylinder. So mine's obviously not the same model as yours, then. I gotta hit the hay now as I want to spend all day checking it over tomorrow. If you or anyone else knows what could be causing the low pedal issue outlined in post #1 then I'll look forward to reading your thoughts in the morning. Night-night!

yes thats the brake reservoir now look at clutch pedal box next to brake pedal box

Kwakerman · Sep 25, 2018

Al2O3 said:
Opened fine for me. Bit grubby that engine bay mind, just saying

Proud to say its NOT mine, just one I googled!

Landlover99 · Sep 25, 2018

jamesmartin said:
yes thats the brake reservoir now look at clutch pedal box next to brake pedal box

Found it, thanks. Tucked away a bit to say the least! Anyway, it's pretty much full; only a few mil below the level line, so that all seems in order. Got something in the back of my mind about checking to see if it changes when the pedal is pushed so will check that (should be a challenge working on my own!)

jamesmartin · Sep 25, 2018

Landlover99 said:
Found it, thanks. Tucked away a bit to say the least! Anyway, it's pretty much full; only a few mil below the level line, so that all seems in order. Got something in the back of my mind about checking to see if it changes when the pedal is pushed so will check that (should be a challenge working on my own!)

now remove the 6 screws holding the plate on the clutch pedal box and check rod nuts havent moved up the rod towards the master cylinder

Landlover99 · Sep 25, 2018

jamesmartin said:
now remove the 6 screws holding the plate on the clutch pedal box and check rod nuts havent moved up the rod towards the master cylinder

You're the boss! We have a shower at the moment so I've come inside. Rotten BBC said it would be sunny and settled all week. Typical!

dag019 · Sep 25, 2018

Might also be worth checking the pedal pivot for wear while you are digging around with the top cover off. You may find that a combination of lots of little things add up to a large amount of slack in the system.
Although it could also be a hydraulic/or clutch fork issue. Does rapidly pumping the pedal have any effect on the point at which it disengages?

Kwakerman · Sep 25, 2018

Landlover99 said:
Found it, thanks. Tucked away a bit to say the least! Anyway, it's pretty much full; only a few mil below the level line, so that all seems in order. Got something in the back of my mind about checking to see if it changes when the pedal is pushed so will check that (should be a challenge working on my own!)

Glad you found it in the end, almost had me confused for a second or two! What colour is the clutch fluid, should be clear(ish), if it is black that is a good sign that it hasn't been changed for a while or that the seals are breaking up.

Landlover99 · Sep 25, 2018

jamesmartin said:
now remove the 6 screws holding the plate on the clutch pedal box and check rod nuts havent moved up the rod towards the master cylinder

Bingo! Well done, sir! That's precisely what's happened. They're only off about a quarter of an inch but it's enough to account for so much more travel on the clutch pedal. Thanks!

Clutch Problem

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