Later style clutch pedal assembly adjustment

Hi all,

I just got a later style clutch pedal assembly to replace my worn and failing 1983 one (I’ll rebuild this, but for now need a quick fix).

I’m having an issue setting it up. It does not have the bolt to set pedal height, instead it has a bolt to adjust the stop height.

It has one of those funny springs that helps hold the pedal down, which is so strong on the return, actually yanks the pushrod circlip out the cylinder and there is no way to get any free play. I have the adjust right down the end of the pushrod (away from the cylinder), but this is still happening.

Also, it seems like the way to adjust pedal height on these newer assemblies is to purely set it through the pushrod, but to my mind, this will only make the problem worse as there will be even more force pulling against the master cylinder.

Before I throw this stupid modern spring in the bin, or drill my new assembly to fit a pedal height adjustment bolt like the old ones had, can someone tell me what’s going on and what I’m doing wrong?! It looks like Land Rover did away with the adjustment bolt at some point during the td5 era. But I’m honestly confused why. And how do I stop the return spring yanking out the pushrod from the master cylinder?

Post #29 may be of use.

https://www.landyzone.co.uk/land-rover/upgrading-clutch-pedal.352327/

Yeah, I’d read this already, this is the set up of my old style unit. In this thread they also say about just adjusting the pedal height by the nuts on the pushrod, but I can’t see that helping the pressure on the master cylinder circlip.

Unless, the clutch fluid provides enough resistance? But it doesn’t feel right having all that pressure pulling against the pushrod, definitely feels like there should be a physical stop like the old style…

Is there a bolt and lock nut on the front face of the pedal box?

Wimblowdriver said:

Is there a bolt and lock nut on the front face of the pedal box?

Click to expand...

Just the bolt for adjusting the stop at the bottom of the pedal travel (I believe this is for setting the amount of assistance the spring provides..?)

The bolt is for adjusting the pedal height. The spring is not adjustable, it simply provides assistance to the effort needed to press the pedal down. Adjustment instructions are in the thread quoted by. @Propman

I’m pretty sure the bolt on the new one doesn’t adjust pedal height, it’s in the wrong part of the fulcrum to do that. My old pedal box has exactly that (bolt that adjusts pedal height), which is why I’m so confused about the new one. I only have workshop manuals up to 300tdi which still used this early design, but looks like part way through td5 production they changed it (not sure though…)

Here’s a picture of the old box. It has the bolt half way up and pushes against a plate mounted just below the trunnion (but above the pivot). The new box has the bolt mounted at the bottom (below the pivot) and acts against the pedal at the base of the pedal stroke. It was my understanding that you adjust this to set the spring - but this is just from watching LOF videos etc - I don’t have a workshop manual for td5 onwards, except one post about adjusting pedal height on the pushrod with the newer types.

I’ll see if I can find it again

Geckomike said:

I’m pretty sure the bolt on the new one doesn’t adjust pedal height, it’s in the wrong part of the fulcrum to do that. My old pedal box has exactly that (bolt that adjusts pedal height), which is why I’m so confused about the new one. I only have workshop manuals up to 300tdi which still used this early design, but looks like part way through td5 production they changed it (not sure though…)

Here’s a picture of the old box. It has the bolt half way up and pushes against a plate mounted just below the trunnion (but above the pivot). The new box has the bolt mounted at the bottom (below the pivot) and acts against the pedal at the base of the pedal stroke. It was my understanding that you adjust this to set the spring - but this is just from watching LOF videos etc - I don’t have a workshop manual for td5 onwards, except one post about adjusting pedal height on the pushrod with the newer types.

I’ll see if I can find it again

Click to expand...

Just this person who had the same issue https://www.landyzone.co.uk/land-ro...ht-adjustment-on-my-td5-r380-gear-box.378633/

It is definitely the bolt for adjusting the pedal height. I have the manuals for the Puma but as I am not at home until the weekend I can’t post the relevant page until then.