Clutch release problem

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solmog

Member
Posts
42
Location
Manchester
I’m a bit baffled with the 200tdi engine conversion I’m doing on an 84 diesel 90 with LT75 box.
Standard defender 200 tdi bolted in without issue, just the usual wiggling around to get the input shaft to line up and slide in place.
I now have a clutch release bearing that seams about 15-20mm short of pressing the clutch plate??
I drilled a couple of inspection holes it the bell housing to double check I had actually fitted the bearing, so I can see clearly that everything is present and correct - clutch bearing arm arm pivot . Pivot arm is pretty much as far back as it can go before the bearing touches the release plate
Any ideas what parts are wrong before I try to fix I would be much appreciated
 
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Nothing at pedal, I realized the slave piston stroke would never reach the end of the push rod when I looked.
Is there supposed to be a Bush between the release arm and the pivot ball of the arm ? Thought the ball of the pivot pin just sat in the dimple on the arm but I’m wondering now if there’s something missing?
 
Still can’t work out why I need to do this but I’m going to make up some shim plates for the pivot stud, which should sort it.
On the plus side it has led me to find that the pivot stud and arm dimple are looking a bit worn so I’ll replace these while I’m at it. I will need to trim down the stiffness on the arm and weld in more compact ribs so I can squeeze it back in in one piece, but it will save taking the gearbox out.
 
One thing I could still do with advice on for clutch set-up
Looks like the head of oil in the clutch master cylinder always pushes the slave out to keep the release bearing touching the pressure plate - so the bearing is always meant to be spinning with the drive.
Is this correct?
 
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