Oh dear I have a hole in my gearbox

Photos have disappeared so I can't check but is it possible you've put the slave cylinder on upside down so it won't bleed properly?

nope - bleed nipple at bottom! Good thought though!

Bleed nipple should be at the top!

What?!?! Top, as in, closer to the sky? (daft question I know, but like to confirm!) I have a horizontally mounted slave cylinder - the fluid id is certainly running clean without air (using bleeder on a compressor). Would this really affect the operation? It would be very nice if the fix was as easy as that (and make me look a little daft in the process!)

rustyrhinos said:

a little daft

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Air rises - so bleed nipples are usually on top.

Thinking about that then, how do you then bleed the clutch? Surely it makes it difficult to access? Or is it supposed to have some sort of extension pipe on the bleed part or something?

The Mad Hat Man said:

Air rises - so bleed nipples are usually on top.

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Yup. Oh dear! So I was wilfully drawing air into the slave cylinder and its sitting at the top of it. I will be swapping them over then - if I remember the thread is the same for the feed and the bleed so just a case of putting it the right way round

Mine's got an extension pipe from the hole the bleed nipple would go in - I'm sure you could make one with a bit of brake pipe and the appropriate connectors. It's in the parts catalogue if you want to have a look at it and its mounting bracket.

Ah! So this little fella then:

594776 BLEED PIPE | shop | www.lrseries.com | L. R. Series c

What I find odd is that I have bled my clutch before and there was no extension pipe...I must have struggled to do it (unless the slave was always upside down - could excess pressure cause the clutch to jam on in the first place, and cause the hole in the box? long shot I suppose)

there's a mounting bracket that supports the end of the pipe part no. 593664 if it's available anywhere.

have you checked the clutch flexi pipe? if its damaged it could be swelling up and taking away some of your clutch travel

oxides said:

there's a mounting bracket that supports the end of the pipe part no. 593664 if it's available anywhere.

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I think I will struggle to find that anywhere, unless on a vehicle that is breaking. I will make a bracket if I cannot find anything - I suppose it can come off the bellhousing bolts.

DefenderOffender said:

have you checked the clutch flexi pipe? if its damaged it could be swelling up and taking away some of your clutch travel

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It is a thought! But I would have thought if was the flexi it would gradually get worse rather than suddenly? And enough to take out 3/4 of the pedal travel, not sure tbh.

To be honest its about all youre left with for what they cost its worth a try to rule it out id highly doubt theres any problems with the clutch itself theres not much to go wrong inside

Yeah, there is not a lot left after that. The only thing I can think is if the selector fork (or whatever it is called) got damaged when everything went kaput.

But first, make the bleed nipple the right way round

Replaced the slave cylinder while I was at it, as it was a non LR item and didnt trust it...but I dare say mounting it the correct way round had more to do with fixing the problem

did plastic socket fall out of release arm they can do it would give you more travel ,have you tried adjusting rod in pedal box

As above, problem solved!

Oh dear. Clutch is lovely. Gearbox not so good. For some reason the 4wd selector does not work - if I have the spring on the lever. it bounces back up when I press it down rather than staying down as it should. And it seems to be in permanent 4WD. Oh, and it jumps out of 3rd and 4th. So I am guessing that the synco gear is also knackered. Cant think of anything to do other than taking the box out and inspecting :\

shafts coming out of front output housing pivot and may be siezed behind cover,remove check that the 2 x shafts move freely,check rear nut on mainshaft is tight in transfer box