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CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

1991 Defender 90 200 Tdi ST Alpine White

Clutch pushrod

Hi.
After changing clutch and flywheel ( Valeo) on my 2002 td5 I been having issues with the clutch..Everything was changed - except slave and master cyl as there was no issues with them.
I had to adjust the master cyl. all the way out to get somewhat decent clutch .... the pushrod I installed is FTC 5199....I was about to change both slave and master + hose, when a friend of mine mentioned that there is 2 different lenghts of pushrod????
Anyone knows something about that😬
Regards
Christian 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

19th Mar 2021 7:22am

Pacha

Member Since: 23 Feb 2020
Location: North Yorkshire
Posts: 772

2008 Defender 90 Puma 2.4 HT Stornoway Grey

There are 2 pushrods, one is 99mm long (FTC5199) and the other is 105mm long (FTC3192). Rgds.

Chris

19th Mar 2021 11:54am

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

Thanks - I Will try FTC3192👍🏻 I bought FTC5199 as it was said to fit all Defender Td5 🤔
Regards
Christian 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

19th Mar 2021 6:51pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6092

I had exactly the same issue when I built my 110 back in 2010....

bought a slave cyl, thinking "ah, Td5 and 300Tdi are the same".... not....

I had a slipping clutch issue from day 1... just looking at the clutch pedal would cause a slip...

Think the slave cylinder also had a deeper "hole" in the end of the piston as well, but as said above, the Td5 is different (shorter) so it gives a little more slack in the system... or just not pressuring the friction plate all the time.

19th Mar 2021 7:13pm

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

Weird.... I have the opposite problem... i have pressure on the pedal but it feels Like the clutch is not pressed all the Way - I am having a hard time changing gears🤔 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

20th Mar 2021 6:55pm

CRJ

Member Since: 12 Mar 2011
Location: Sealand - Denmark
Posts: 253

I just changed the master cyl.... I got a brand new car 😀.. After close inspection there was a tiny bit of brake fluid on the pedal. I was certain it was the pushrod or something else as the movement in the clutch pedal felt normal...guess it did not produce enough pressure to function properly.
Regards
Christian 88 Ser. 3 1980 -sold
Puma 130 - 08- sold
90 200tdi 1991 - sold
88 Ser. 3 1977 200 TDI
110 CC 2003

28th Mar 2021 3:11pm

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