Pushed my luck - clutch

The last couple of months found the clutch pedal sticking occassionally, been meaning to replace slave and master cylinder..... one of the jobs on a list of 500 things I didnt get round too!
After scoffing my face at me mom n dads jumped in the 300tdi disco to find the clutch pedal hard on the floor and just a major grinding as I tried to engage 1st!

Checked fluid level and its between min and max so im steering towards replacing the slave cylinder....

Any advice?

Thanks in advance

not sure about your senario but when my slave cylinder went i had no fluid left at all

I am thinking it all depends on whether the cylinder is stuck open or closed?....

My guess would be that the clutch fork pivot has pierced the clutch fork.

Unfortunately if I'm right you have to have the gearbox off.

Parts needed:

1 x HD reinforced clutch fork;
1 x clutch release bearing
2 x slipper pads
1 x plastic clip for bearing
1 x plastic retaining cup for actuating rod.

Those parts are just relating to the releasing mechanism but whilst you have the gearbox split, why not put a clutch in at the same time?

Oh god I do hope your wrong biglad!

I have just picked up a slave cylinder from craddocks ready to do the job tomorrow!

Where am I looking to see if the fork is pierced?

PS

biglad the clutch pedal stil operates up and down just little resistance...

MikeDISCO said:

Oh god I do hope your wrong biglad!

I have just picked up a slave cylinder from craddocks ready to do the job tomorrow!

Where am I looking to see if the fork is pierced?

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Hi Mike, it's ounding more and more like a knackered clutch fork. Before we go too far down this road, You need to understand that the total bill for these parts will be no more than £25-ish.

By all means change the slave cylinder first, but you may well find that the clutch operation remains the same.

To change the clutch fork and it's bits you need to split the bellhousing away from the engine. This is not at all hard, you just have to be methodical.

Do a Google search for "TDi 300 Discovery clutch change" and you'll find an excellent 'how to..'.

Cheers biglad, like I previously said I have already purchased the slave so I will go ahead and change that and see what happens.

I have found a good instruction made by les henson off LR4x4.

I think I am more than capable its the kit and location I will struggle with.

I live on a terraced street with no drive or garage, I have bottle jack and axle stands.

Unless there is some kind hearted soul that had a garage and experience willing to help me out for some beer tokens?

MikeDISCO said:

Cheers biglad, like I previously said I have already purchased the slave so I will go ahead and change that and see what happens.

I have found a good instruction made by les henson off LR4x4.

I think I am more than capable its the kit and location I will struggle with.

I live on a terraced street with no drive or garage, I have bottle jack and axle stands.

Unless there is some kind hearted soul that had a garage and experience willing to help me out for some beer tokens?

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They are easy to fit on roadside as long as you don't mind laying on a cold floor. A second person to help with bleeding it would help. If yer on yer own then an easi-bleeder will do it.

MikeDISCO said:

Cheers biglad, like I previously said I have already purchased the slave so I will go ahead and change that and see what happens.

I have found a good instruction made by les henson off LR4x4.

I think I am more than capable its the kit and location I will struggle with.

I live on a terraced street with no drive or garage, I have bottle jack and axle stands.

Unless there is some kind hearted soul that had a garage and experience willing to help me out for some beer tokens?

Click to expand...

Doing the slave at the roadside is not a problem. I found that splitting the gearbox required another pair of hands plus two trolley jacks.

thebiglad said:

Doing the slave at the roadside is not a problem. I found that splitting the gearbox required another pair of hands plus two trolley jacks.

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I usually use 2 extra pairs of hands and one trolley jack.

hahaha! yes slave cylinder wont be a problem outside me house, I only hav one trolley jack though not sure if I am going to undertake the suspected problem though, really dont fancy laying on me back in the freezin cold!
I will see what happens tomorrow, and if it the big job to undertake Im sure when i get the quote from a local garage i will be laying some blankets on the road and doin it me self cuz im a tight arse n cant bare paying a kid at a garage £35 an hour in labour something i can do myself.

I have read on some others pages about propping the crank pulley up some a piece of wood to keep the engine aligned.... any truth in this?

MikeDISCO said:

hahaha! yes slave cylinder wont be a problem outside me house, I only hav one trolley jack though not sure if I am going to undertake the suspected problem though, really dont fancy laying on me back in the freezin cold!
I will see what happens tomorrow, and if it the big job to undertake Im sure when i get the quote from a local garage i will be laying some blankets on the road and doin it me self cuz im a tight arse n cant bare paying a kid at a garage £35 an hour in labour something i can do myself.

I have read on some others pages about propping the crank pulley up some a piece of wood to keep the engine aligned.... any truth in this?

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If you mean propping up the front of the engine, this is absolutely key to making the reassembly go well. That's where I use the second trolley jack as it gives a little adjustability.

I put the trolley jack (plus a piece of wood) under the front of the engine just in front of the sump, under the timing belt case.

thanks again biglad, would my standard bottle jack do this well or not advised?

anyone in staffordshire fancy a little job this weekend? ;o)

MikeDISCO said:

thanks again biglad, would my standard bottle jack do this well or not advised?

anyone in staffordshire fancy a little job this weekend? ;o)

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You could do it with a bottle jack but you'll need to raise it up some to reach the engine and you'll have to work out a method of stabilising everythign as the bottle jack could fall over.

That's one reason why I say use a trolley jack, they are much safer.

You might be able to use an axle stand????

maybe.. i like your comment of being able to adjust it with a jack though, i wil try and beg steal or borrow one.

Hey i just had a very optimistic thought, the slave cylinder may fix it tomorrow haha!

but im pretty sure im going to have a busy weekend, any ideas roughly how long it should take me?

would this clutch kit from craddocks give me all the parts i need?

STC8358G COMPLETE CLUTCH KIT 2.5D 2.5TD 200/300

biglad one thing i did forget to mention there is some fluid ( quite allot ) on the road underneath the slave cylinder area......

MikeDISCO said:

biglad one thing i did forget to mention there is some fluid ( quite allot ) on the road underneath the slave cylinder area......

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Well, maybe you'll be lucky ??

I would go out and have a look but im at me mom n dads but there was definately fluid on the floor, i hope im lucky BL i really hope so, would make a blummin change!
Any tips or instructions for bleeding after the cylinder change?