Clutch - Tdi 200 Disco1 1993

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Ausman

New Member
Posts
15
Location
Brisbane
I have just refitted a reconditioned gearbox and transfer case replacing the clutch with a heavy duty one, after problems bleeding the clutch replaced the clutch master cylinder and slave cylinder, the clutch would still not release.
Removed the thin spacer from between the slave cyl'd and housing still not releasing.
I made up a three holed plate with a threaded bar in the middle, removed the slave cyl'd and fitted the plate, screwed in the threaded bar and pushed the clutch pin and arm fully approx 22mm.
Still cannot engage the gears, lots of grinding, I put it into reverse/low and started the engine it drove back but stopped when I put the brakes on, it sounded like the clutch was slipping/rubbing, released the brakes and it drives off again.
Then screwed out the threaded bar on the temporary brkt releasing the clutch lever, did the same test starting in gear applied the brakes and the engine stalled.
It looks to me that the clutch pressure plate is not being released fully?
If you can help it would be appreciated, I am considering going back to therapy as electric shook treatment sounds a better alternative to pulling out the f'in gearbox again.

:(:D:(:D:(
 
The Haynes Manual lists that the clutch pressure plate be fitted with the protruding side to the flywheel, I have got hold of a Workshop Manual that lists that the clutch pressure plate be fitted with the protruding side to the gearbox, O dear how sad never mind! Maybe not allowing the old pressure plate to slide off before checking which way round it was would have been a good idea!
:screaming_bug_eye_f:screaming_bug_eye_f
 
All is good and happy in Disco land. I have removed the gearbox and transfer case assembly, removed the clutch and turned the fiction plate over so that the protruding side faces the gearbox - opposite to the instruction in the Haynes Manual 1989 - 1998 Discovery.
I am not in to advertising my mistakes and it maybe obvious to some but the consequence of assembling the clutch as per the instruction in the Haynes manual is day spent fixing discos not driving them.
:D
 
All is good and happy in Disco land. I have removed the gearbox and transfer case assembly, removed the clutch and turned the fiction plate over so that the protruding side faces the gearbox - opposite to the instruction in the Haynes Manual 1989 - 1998 Discovery.
I am not in to advertising my mistakes and it maybe obvious to some but the consequence of assembling the clutch as per the instruction in the Haynes manual is day spent fixing discos not driving them.
:D


It does say on the plate, quiet clearly. "FLYWHEEL SIDE"... I would believe that over the Haynes manual anyday...

Lesson learnt... must say, many must have done it over the years though.. At least you know how to get the clutch off, :D
 
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