Series 2 Fitting a LOF clutch

cornish rattler · Nov 8, 2023

Hi guys
I've decided to fit a LOF clutch kit ( 200tdi ) which arrived today as with the high gearing and having a roof tent perminantly fitted my clutch tries to slip when setting off, so today i made a start on removing the engine so once its out i can replace the clutch assy and also check if anything else has caused it to try and slip but it has been in for the past 5 yrs so probably due anyway

Wildefalcon · Nov 8, 2023

Td5 clutch pedal? And lof hydraulics? Goodrich Flexi hose?

steve2286w · Nov 8, 2023

Rumour has it it can be fitted just moving gearbox backwards, are you still happy with higher gearing, any downsides you have found

300bhp/ton · Nov 8, 2023

steve2286w said:
Rumour has it it can be fitted just moving gearbox backwards, are you still happy with higher gearing, any downsides you have found

Not sure what gearing the op is running. I fitted 3.54:1 diffs to my 200Tdi Series III. Had I kept the vehicle I was planning on going back to 4.75:1 diffs.

The taller diff gears do give better cruising ability. But as the op says 1st gear pull away means quite a bit of clutch slip. I also found that the 3.54 diff also created an rpm gap between 3rd and 4th. 4th was too high to pull 30mph on a slight incline, but 3rd always felt like you were revving it.

Overall the 3.54 diffs just didn't drive as well and made it feel less peppy. I also found that the 3.54 diffs ruined the low 1st crawl speed off road.

I believe there is a lower low range gearset that could be used that would help off road. I think I would have either gone down the over drive route or maybe taller high range gearing with standard diffs. More costly than just different diffs, but I think a better long term solution. An ovderdrive would also give you potentially 8 forward gears too, so a lot more flexible.

Dodgy Den · Nov 8, 2023

I fitted an uprated 200bhp capable LOF clutch on my TD5 DEF to cope with the remap. It worked fine with new master and slave cylinders but it was fairly stiff to use. I also bought the LOF spring but didnt get to fit it which is said to resolve the pressure needed on the clutch pedal. Very expensive to buy i thought but it all went on without a hitch.

Wildefalcon · Nov 8, 2023

The series clutch is heavier than the td5 as standard, so the lof spring and td5 pedal is worth doing imho.

cornish rattler · Nov 9, 2023

marjon said:
Are you that dedicated to finding a rusty nail to walk around in the rain.

J

steve2286w said:
Rumour has it it can be fitted just moving gearbox backwards, are you still happy with higher gearing, any downsides you have found

Yes i'm still happy with it aspecially with the Roamerdrive fitted

cornish rattler · Nov 9, 2023

300bhp/ton said:
Not sure what gearing the op is running. I fitted 3.54:1 diffs to my 200Tdi Series III. Had I kept the vehicle I was planning on going back to 4.75:1 diffs.

The taller diff gears do give better cruising ability. But as the op says 1st gear pull away means quite a bit of clutch slip. I also found that the 3.54 diff also created an rpm gap between 3rd and 4th. 4th was too high to pull 30mph on a slight incline, but 3rd always felt like you were revving it.

Overall the 3.54 diffs just didn't drive as well and made it feel less peppy. I also found that the 3.54 diffs ruined the low 1st crawl speed off road.

I believe there is a lower low range gearset that could be used that would help off road. I think I would have either gone down the over drive route or maybe taller high range gearing with standard diffs. More costly than just different diffs, but I think a better long term solution. An ovderdrive would also give you potentially 8 forward gears too, so a lot more flexible.

Yeah i've tried everything, from when the restoration inc 200 tdi conversion was done, HRTC with 3.54 diffs, then HRTC on its own with 4.71 diffs, then back to just 3.54 diffs then later added a Roamerdrive, which seems to be the best option for me, everything was done running 235/85x16 tyres which i think was more or less the same gearing and access drag as probably 3.54 diffs was on there own

cornish rattler · Nov 9, 2023

Wildefalcon said:
The series clutch is heavier than the td5 as standard, so the lof spring and td5 pedal is worth doing imho.

Yeah LOF say bed the clutch in first then fit thier master cylinder, never heared about the td5 pedal before i take it you mean the pedal box and pedal i will also replace the slave cylinder as well as both have been on best part of 5 yrs anyway

Wildefalcon · Nov 9, 2023

Yep, td5 box is better leverage.

cornish rattler · Nov 9, 2023

Wildefalcon said:
Yep, td5 box is better leverage.

Nice one i will go with that

Wildefalcon · Nov 9, 2023

I'll get a photo tomorrow. Puma is the same. Pop the lof spring in when it's in the bench.

cornish rattler · Nov 9, 2023

Wildefalcon said:
I'll get a photo tomorrow. Puma is the same. Pop the lof spring in when it's in the bench.

Will do

cornish rattler · Nov 11, 2023

Engine is out now so will fit new clutch assy tomoz as i'm in work later

Wildefalcon · Nov 11, 2023

Forgot this yesterday. Puma pedal.

cornish rattler · Nov 12, 2023

Wildefalcon said:
Forgot this yesterday. Puma pedal.

Nice one, i take it the pedal is in a better position

Wildefalcon · Nov 12, 2023

Just better leverage, and the over centre spring works like a gas strut on a tail gate.

lynall · Nov 12, 2023

Weld the grippy bibbles onto the new pedal before fitting to the car.

Wildefalcon · Nov 12, 2023

Excellent point, or swap the series pedal flat across.....

dag019 · Nov 21, 2023

cornish rattler said:
Nice one, i take it the pedal is in a better position

Wildefalcon said:
Just better leverage, and the over centre spring works like a gas strut on a tail gate.

It is the over centre spring that makes the difference on the pedal. But it is not just a td5 pedal, both 300tdi complete bulkheads I have bought have also had the later style pedal construction made form a single flat plate rather than the c-channel. Any model clutch pedal which is this later style (pictured above by @Wildefalcon ) will work and give a better feel.

Series 2 Fitting a LOF clutch

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