Td5 manual 'box clutch problems!!!!!!

stevo88 · Aug 8, 2011

right then...... i've changed the clutch on this disco II (****part HD assembley (on customers orders) ) and everything has gone sweet n dandy, lined clutch up, fitted n tightened cover to 25NM re fitted box, attatched the slave to the bell housing...... and nothing...... have had the box out again to make sure everything is in its place, and it is, its had all new clips n bushes on the fork, all grease in all the right places, just can't get a pedal, got a slave on its way as there is a slight weep from round the piston, but not enough of a leak to not be able to get a pedal!!!!!

master seems ok, am i pulling my hair out for something i may have overlooked? is it a common thing this? can anyone offer any tips or advice pleeeeaaaaaaaaaassseeeeeeeee?????

jamesmartin · Aug 8, 2011

presume rods right one ,and have you some clutch or nothing,slight weep is enough to let air in on return stroke loosing pedal on down,does it splash in master when pumping pedal if so it needs replacing did you put plate in right way round as td5 is opposite to normal

stevo88 · Aug 8, 2011

jamesmartin said:
presume rods right one ,and have you some clutch or nothing,slight weep is enough to let air in on return stroke loosing pedal on down,does it splash in master when pumping pedal if so it needs replacing did you put plate in right way round as td5 is opposite to normal

yeah the rod is the right one, clutch plate has flywheel side against flywheel (it was written on the plate) there isn't any bubbles in the master on return stroke, but it feels a bit weak, for example... holding my finger in the slave cylinder when the pedal is pushed it should push my finger right out shouldn't it? but it seems very week? is that master or slave thats at fault?

ricksam · Aug 8, 2011

do know these are right bastard to bleed if you get air in,did mine few week back and took ages to get pedal,pumped like **** for ages,

stevo88 · Aug 8, 2011

yup, its had over a litre of fluid put through it an still the same

jamesmartin · Aug 8, 2011

too weak try bleeding master first

sierrafery · Aug 8, 2011

disconnect pipe from the master and try then the finger test...if it doesnt push your finger away replace the master... though it's healthy to replace both cylinders at the same time.... untill then stick the pedal to the floor overnight with a piece of wood against the seat or something

tony3001 · Aug 8, 2011

had the same problem after fitting a new clutch to mine I didn't touch anything on the hydraulic side but couldn't get a peddle tried a slave cylinder first ,still no good then put a new master cylinder on and still could not get it to bleed off ,I went through about a gallon of brake fluid ,fitted a new pushrod
I tried a pressure bleeder but the cap wouldn't seal properly and ended up with fluid all down the servo and chassis
I ended up buying a vaccuum pump from the snapon man to try and suck the fluid through ,I think this method did work but I also tried keeping the pedal pressed down overnight using a length of wood which may also have helped
so to sum up this was the worst clutch job i've ever done and I totaly understand you're problems
I thought after I replaced the slave and Master cylinders the thing would be an easy fix but I was wrong so I'm not sure if I wasted money on these bits
mine's working now still heavy and a slight judder when pulling away
sorry I can't give any more advice other than perserverance ( I swore lots after removing the gearbox just incase to find everything fine inside )

stevo88 · Aug 9, 2011

tony3001 said:
had the same problem after fitting a new clutch to mine I didn't touch anything on the hydraulic side but couldn't get a peddle tried a slave cylinder first ,still no good then put a new master cylinder on and still could not get it to bleed off ,I went through about a gallon of brake fluid ,fitted a new pushrod
I tried a pressure bleeder but the cap wouldn't seal properly and ended up with fluid all down the servo and chassis
I ended up buying a vaccuum pump from the snapon man to try and suck the fluid through ,I think this method did work but I also tried keeping the pedal pressed down overnight using a length of wood which may also have helped
so to sum up this was the worst clutch job i've ever done and I totaly understand you're problems
I thought after I replaced the slave and Master cylinders the thing would be an easy fix but I was wrong so I'm not sure if I wasted money on these bits
mine's working now still heavy and a slight judder when pulling away
sorry I can't give any more advice other than perserverance ( I swore lots after removing the gearbox just incase to find everything fine inside )

ITS SORTED

it was the slave that was fooked, bled it for a good hour-2hour this mornin, to no avail, put a new slave on it an it bled up a dream

Td5 manual 'box clutch problems!!!!!!

stevo88

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jamesmartin

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stevo88

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ricksam

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stevo88

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jamesmartin

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sierrafery

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tony3001

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stevo88

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