Disco 2 Changing gears not always "possible"

I have an issue in my manual Td5, that the gear changes are not really that smooth and sometimes, especially when the gearbox is warmed up, that I am not able to engage some gears, especially reverse. The only option to be able to put it into gear would be to put the transfer case in neutral and then I can engage which ever gear i want. Putting the TC back in high seems to be less smooth than usual in this case. Till now I changed the slave cylinder (fitted the V8 one to make the clutch pedal a little lighter) and changed the clutch master cylinder because the spring was broken.

Any ideas what would be causing this?

thanks
Mark

You may find your symptoms listed here:

https://www.ashcroft-transmissions.co.uk/frequently-asked-questions/r380-faq-s.html

nice, thanks for the link. I did not see the exact symptoms listed, unfortunately, but still a very handy link to have

Give them a call and explain the symptoms to them.
You'll find them to be quite helpful.

So aschroft guy said that it should not be an issue with the gearbox it self but with the clutch system. A local deal said that since I had fitted a bigger bore slave cylinder (after fitting a HD clutch, so that I could have a softer clutch pedal), I could run into these sort of issues. I do not believe it though since this only started after replacing the master cylinder.

One thing I noticed is that I only have problems when the engine is on. If I can engage reverse, I just switch it off and then I can engage reverse without problems... Any ideas????

I take it that you have tried replacing the slave cylinder with the original and the clutch pedal feels ok. Does the alternative slave cylinder produce the sam length of travel at the clutch fork for the amount of travel at the clutch pedal. First thing I would do is try the original slave cylinder.

so, while removing the clutch slave, I found a bit of a surprise... the push rod and the clip came out with the slave. Some say that the clip is only useful when installing a new slave cylinder and it should stay in place once installed. i used a little grease to hold the pushrod in place while I installed the slave. Will this work or better to open it again and try to fit the clip?

changed back to standard slave and now issue seems to be resolved, although second does not always feel smooth. I plan on changing the plastic yoke bush, maybe it makes a difference