clutch slave push rod stuck

can someone please suggest a solution to my problem below:
Decided to replace the clutch slave on my defender 200tdi. the old one came off easily but as the push rod was not held in place with the plastic clip it came off from its normal position. However, I'm unable to pull the push rod out because the ball end seems to be stuck. Tried pulling it with the long nose pliers but no luck. Has anyone had this problem and is there an easy way of removing the push rod without splitting the engine and gearbox.

Please help!!

Why do you need to pull the push rod out if you are just replacing the slave cylinder..?

JonneP,
...............because the ball end of the push rod is not located/seated correctly. There was no plastic clip to hold the push rod in place.

has push rod dropped down inside bell housing or is end poking out of hole for slave

Soz dunt help much but when I do a clutch I always put a cable tie on the pushrod/clip to stop this happening !

Some have managed after hrs of farting about to get a new clip and rod in but it's a reight bastid of a job

The push rod has not dropped into the bell housing. It is still poking out of the slave hole. Tried recovering it with a long nose but no luck, it seems the ball end is stuck behind the lever arm.

it must have pushed through it then as normally it comes away with slave if your noit careful and hold it in place whilst removing slave ,you need to drop the box to change release arm

I've never dropped a gear box on a landy. Is it a difficult job and can it be done with the engine still in? Any advice on how to approach this task?

yes , easiest way is with engine crane through passenger door with chain on drivers side top bolt securing t/box to g/box and support under rear of engine after allowing boxes to drop at the rear

it can be done with the engine still in mate, simply take the floors and gearbox surroung out to get better access, un-do bell-housing bolts, remove exhaust, gearbox mounts, props and gearstick.. oh and also youll have to remove the top box from the dif slelector// have two or even better 3 people to do it and then put blocks, and jacks underneath so you can lever it off the belllhousing backwards then dropdown on the jacks. once fixed, alot of fiddling, swearing and skinned knuckls and it willg o back in.. NOT one to do on your own though..

many thanks guys. Ive had a good look (as best as I coud) at the lever arm through the slave hole and it looks ok. the ball end of the rod seems to be stuch beween the edge of the arm lever and the housing. I'll have 1 more go at recovering this push rod before spliting the g/box. I'll let you know how I get on.

put pressure on the rod to try and lever it away (acting as the clutch slave yourself) ?

Tried to put pressure by acting as a clutch slave myself as abcdedd suggested but very difficult so I built a tool to push the arm as a slave would do and managed to retrieve the push rod. That has saved me a lot of work. installed a new slave without the plastic clip to hold the push rod. Obviously I didnt locate the push rod properly because the slave went pop when I bled it! So the question now is, is there an easy way to install this plastic clip? Secondly , is the slave still usable with a new repair kit? it was a new one but I can now see some light scoring on the inside of the cylinder. is it better to buy a new one. thirdly which make is better delphi or lucas trw.

Put it bacl together and have another try, light scoring should not be a problem as long as it don't leak when its in there.

You can reinstall the rod AND clip through the slave hole if you have the patience, otherwise use long nose pliers to hold the rod in the ciorrect position whilst inserting the slave cylinder assembly and it should be fine without clip

Hi, there
managed to install the clip and push rod through the slave hole after trying for 2 hrs. Its not a very snug fit . Is that normal? Also I noticed that the arm travels a bit - about 3-4 mm when lightly pushed as a slave would. is that normal? please someone tell me I haven't got a bigger problem !!!! I have installed the slave but not filled it yet. Hopefully all should be well when I bleed it. any advice on the best way to bleed it?

thet are a poor fit clip holds very loosely movement is just gap between release bearings furthermost rearward travel and clutch diaphragm forwards

jamesmartin said:

thet are a poor fit clip holds very loosely movement is just gap between release bearings furthermost rearward travel and clutch diaphragm forwards

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Hiya James - You been away for a few days - anywhere nice??

hi ,no unfortunately not ,laptops been away to be mended for a week ish

jamesmartin said:

hi ,no unfortunately not ,laptops been away to be mended for a week ish

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too much porn does that.

3.5 efi said:

too much porn does that.

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whats too much