Gearbox/clutch td4 2002

Hi, problem with clutch/gearbox. Hardly any clutch struggling to get reverse gear clunking into other gears. Either you go for reverse and up on 4th. When you do get it it grinds then you have to force it in. Alright when cold but as soon as it gets hot that's when the trouble starts. Any sensible ideas. This could be the straw that breaks the camels back.

Have you checked the fluid level? If you balance the engine RPM with the road speed for the gear you want, then you'll do less damage to the gearbox. Forcing the gears will only cause more damage.

TD4 clutch low bite seems a recurring problem.
I have just had a re-read of my and others posts on the matter and it appears that the following are common issues:
1. Worn or cheap non OEM master cyliner does not present enough movement of fluid to operate slave fully.
2. Push rod a bit too short (again maybe cheap master). 4mm extension on push rod fixes it.
3. Air in hydraulics - bleed and try again. Sometimes an air lock in the mast, remove master, take off push rod and operate piston fully to bottom of cylinder to expel air fully.
4. Slave leaking (last resort as this is a gearbox out job).

Also - an easy test is to disconnect the master quick release and see if you have a solid pedal, if not bleed system and purge any dirty fluid from slave in the process.

There's a few things to try !

Thanks Guy's

Hi Andyfreelander/Nodge68,
Just an update, Changed the master cylinder out, no joy still the same issues. Now found another problem the clutch pedal box? if that is what it's called, is there a way of taking it out, without taking out half the lower dashboard out1st? One of the pedal stops has been rubbing on the pedal spring so that needs to be replaced, I have another pedal box, it's only got 3 nut's to undo ha,ha,ha. yes 1 is easy enough, but the other 2 are right, well you can guess the rest, Andy I'm still up for having them wheels off you if they are still available? I have just ordered a clutch, slave and dual mass flywheel from muddy mods, Chell and Warren have been great with advice pointing me in the right direction, thanks Nodge68. They have organised a muddy mod weekend at billing offroad circuit it would have been great to get over there for the weekend. Always next year. Any ideas about this clutch pedal box?

Wheels await you when you are available !

Bad news is, only ever taken the clutch box and pedal out once. Dash was already out and it was easy !! Sorry
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