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Appleby

Member Since: 03 Apr 2012
Location: Bristol
Posts: 74

Clutch Problems

Hi everybody!

My 02 Td5 has just ticked over 100k miles and started to develop the first ever issue I've had with it.

The clutch is sticking when fully depressed and I can't get it in or out of gear. If I pop the pedal back up using my foot I can then get it in and out of gear. The gear changes can be really stiff too.

If I sit with the clutch pedal pressed and in gear with the brake pedal pressed hard.,the clutch will slowly engage and stall the engine. Does this sound like symptoms of a leaky clutch cylinder? Can I just dump some more DOT4 in there to get me 30 miles over the weekend?

1st Nov 2017 4:03pm

Mash

Member Since: 09 Feb 2015
Location: Guernsey
Posts: 1674

Yea topping up should be fine

Most likely be the slave cylinder leaking which is an easy job. 90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html
110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html
52HG25 lightweight https://www.defender2.net/forum/topic72342.html
D3 Hse - Fiona
Capri 2l S - Anna

Think I might have a problem............

1st Nov 2017 4:21pm

TechnoTurkey

Member Since: 25 Jul 2016
Location: Worcestershire
Posts: 88

2005 Defender 110 Td5 CSW Zambezi Silver

Easy apart from bleeding it!

2nd Nov 2017 12:28pm

Vogler

Member Since: 02 Nov 2014
Location: Brussels
Posts: 309

Use reverse bleeding. Introduce DOT4 from below using a large syringe and make sure to get some out of the reservoir so it doesn't spill.
Also, it apparently helps to get rid of the air by keeping the pedal depressed for a night.

Greetings,

Joris

2nd Nov 2017 12:34pm

DieselBeast

Member Since: 27 Sep 2017
Location: UK
Posts: 33

Is the Td5 clutch slave cylinder the same external type as the 300 tdi?

2nd Nov 2017 8:50pm

Low-Range

Member Since: 30 Sep 2016
Location: BC
Posts: 41

old school oil can

You can also use the old school oiling can with a little flexible tube to push up fluid...no air trapped in line.

AND IT"S CHEAP

2nd Nov 2017 10:04pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

DieselBeast wrote:
Is the Td5 clutch slave cylinder the same external type as the 300 tdi?

clutch slave cylinder in TDI engines

ftc 3911 To V TA 9975715 + FRC2402

ftc 5072 to G 56A 0669086K + FRC2402

ftc 5202 from G 56A 0669086K + FRC2402

clutch slave cylinder TD5

FTC 5202 TD5

3rd Nov 2017 8:01am

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2758

After you've fitted new parts and bled the system, you will most likely find that no matter how much you bleed/reverse bleed it, the clutch engages right at the bottom of the pedal.
Wedge the pedal down overnight and that should sort it.

3rd Nov 2017 8:24pm

williamthedog

Member Since: 29 Dec 2012
Location: south wales
Posts: 3441

Just what you had to do with
the old minis

3rd Nov 2017 9:24pm

LinDens90XS

Member Since: 24 Feb 2012
Location: Merseyside
Posts: 83

2003 Defender 90 Td5 XS CSW Bonatti Grey

My penny worth. It may be just as well to change the master at the same time as when one goes the other is never far behind. Regards
Dennis.

9th Nov 2017 9:21pm

Oakseywick

Member Since: 20 Dec 2014
Location: Cirencester
Posts: 1000

I recently had a new clutchfix HD1 clutch and valeo dmf fitted I have noticed bitepoint very low to floor but also that the pedal has drop a inch or so and does return right to top position. You can move the pedal up a bit with your foot, any advice? Would this be sorted by wedging pedal down over night as lightning suggests

9th Nov 2017 10:24pm

agentmulder

Member Since: 16 Apr 2016
Location: Outer Space
Posts: 1324

Never tried this but next time I will..

So I thought to catch air bubbles in the line from the syringe/oil can install a t-joint with a short section of terminated hose at the apex of the hose.

Solved the bowel problem, working on the consonants...

9th Nov 2017 10:36pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2758

Oakseywick wrote:
I recently had a new clutchfix HD1 clutch and valeo dmf fitted I have noticed bitepoint very low to floor but also that the pedal has drop a inch or so and does return right to top position. You can move the pedal up a bit with your foot, any advice? Would this be sorted by wedging pedal down over night as lightning suggests

Try it tonight and see! It has always worked for me.

10th Nov 2017 2:03pm

4RF RDS

Member Since: 19 Jul 2015
Location: Ottawa
Posts: 932

2000 Defender 110 Td5 XS CSW Epsom Green

Defo sounds like you’ve got a slave or master leak. Check fluid level, fill and bleed then determine what is leaking and replace or rebuild. 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)

10th Nov 2017 3:33pm

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