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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
DEFENDER 300TDI - Gear Stick Will Not Go Into Any Gear
Greetings Rovers

Recently I was met by the dreadful "Rock Solid Clutch Pedal", turns out the cause of issue was the rod piercing straight through the fork which after reading the internet seems to be a common issue with these defenders.

After loads of swearing and sweat I managed to separate the gearbox from the engine revealing the fork.......but I just can't seem to find the right way to remove the fork.

Can any one explain to me if there is a technique to removing it or is there a bolt or clip fastening I'm not seeing??

I added a picture below showing the fork I'm referring to as well as what the damage of the fork looks like, the picture posted was taken from the internet but it literally looks exactly like how mine looked, it clearly shows the shaft piercing through the fork.

Click the link below to see the picture.

https://www.defender2.net/gallery/albums/u...5_9771.jpg

Last edited by BajanRover on 17th Sep 2022 1:05am. Edited 3 times in total
Post #964916 13th Sep 2022 7:07pm
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ibexman



Member Since: 13 Dec 2008
Location: Essex
Posts: 2945
United Kingdom 
The clutch push rod has pierced the fork big hammer needed
Post #964927 13th Sep 2022 8:35pm
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
ibex

You are right, I used a my flat head screw driver and a hammer to pry the fork off the rod.... took some elbow grease and swearing but I got it off.

Not looking forward on getting the box mated back to the engine but nevertheless the culprit was removed and a new modified fork will be installed.

I will do as the internet has suggested and weld a piece of metal onto the back of the new fork to prevent this from ever happening again Cool .
Post #964931 13th Sep 2022 9:35pm
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
ARRRGGGHHH Banging Head

Just as I thought it was over.... it wasn't.... I changed the clutch fork, reinstalled the gearbox onto the engine, bolted up both propshafts, bled the clutch fluid by the slave cylinder...

Now I am unable to shift the gear stick into any gear, it literally refuses to go into gear, however when I put the transfer gear into Neutral the gears go in but obviously there's no drive since T-Case is in Neutral.

With the clutch pressed in, when I try to put it into gear, I can feel the truck trying to move forward while I am trying to put it into gear. So, it's almost acting as though there was no pressure on the clutch pedal even though everything was bled and had good pressure to the pedal.

I am really exhausted from the time taken on this truck, been at it for the last 2 days now and considering just selling it Thud
Post #965244 16th Sep 2022 4:56pm
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Dave T



Member Since: 07 Jun 2013
Location: Glasgow
Posts: 490
United Kingdom 1994 Defender 90 300 Tdi SW Cairns Blue
I would start with bleeding the clutch some more, when I changed my slave it took far longer than I was expecting to get a good pedal 2015 RRS Autobiography SDV6
1994 Def 90 300tdi
Post #965267 17th Sep 2022 5:57am
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htb2



Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 531
Wales 
Did you disturb the clutch plate, whilst you were in there?
Did you fit release bearing after changing release fork, it has been known forget to fit it.
Post #965269 17th Sep 2022 7:35am
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3421
Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
What is baffling is that the OP says he has a good pedal pressure.
Could the friction plate suddenly stick to the flywheel or pressure plate?
If clutch was replaced, was the friction plate installed correctly - they have a flywheel side to have clearance for the friction plate springs.

I think leaving the thrust bearing out will get a rock solid pedal as I doubt the fork is able to reach the pressure plate fingers. But if they did would make a horrendous noise if the engine is running. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #965273 17th Sep 2022 8:42am
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
htb2 wrote:
Did you disturb the clutch plate, whilst you were in there?
Did you fit release bearing after changing release fork, it has been known forget to fit it.


Yes, I fitted the slave rod onto the clutch fork with the clip, then pushed the clutch fork onto the long nipple inside of the gearbox, then I slid the release bearing on.
Post #965309 17th Sep 2022 5:50pm
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
Dave T wrote:
I would start with bleeding the clutch some more, when I changed my slave it took far longer than I was expecting to get a good pedal


I bled it more again today and I am getting good pressure and I can also hear the fork pressing on the pressure plate when I press the pedal which to me usually indicates the slave rod is pushing the fork onto the pressure plate...

Do correct me if my presumptions are wrong.
Post #965311 17th Sep 2022 5:52pm
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
htb2 wrote:
Did you disturb the clutch plate, whilst you were in there?
Did you fit release bearing after changing release fork, it has been known forget to fit it.


Dinnu:

I am not 100% sure if I disturbed anything to be honest, certainly I didn't touch them with my hands whatsoever.
Post #965312 17th Sep 2022 5:58pm
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
Dinnu wrote:
What is baffling is that the OP says he has a good pedal pressure.
Could the friction plate suddenly stick to the flywheel or pressure plate?
If clutch was replaced, was the friction plate installed correctly - they have a flywheel side to have clearance for the friction plate springs.

I think leaving the thrust bearing out will get a rock solid pedal as I doubt the fork is able to reach the pressure plate fingers. But if they did would make a horrendous noise if the engine is running.


I agree with you but in this case, I didn't change the clutch nor pressure plate, all I did was replaced the clutch fork and the clip that holds the slave rod to the fork.
Post #965313 17th Sep 2022 6:01pm
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3421
Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
Your description sounds right.

Could it be you got a cheap fork and is bending under pressure? Perhaps that is the sound you are hearing?

Could you have spilled something on the clutch? Or it got wet?


Had a few engines whose friction plate stuck to flywheel due lack of use, but usually can break the bond by pressing the clutch pedal, put in gear, keep pedal pressed down and try to start the engine. It may damage starter, crash you in a wall or even worse so do at your own risk. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #965344 18th Sep 2022 1:29am
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BajanRover



Member Since: 12 Feb 2021
Location: Barbados
Posts: 74
1995 Defender 130 300 Tdi HCPU Alaska White
lol yea so I probably won't do that but to answer your question no.... I didn't get the clutch wet.

So, it is looking like I may have to pull off the box again and inspect....

I do notice some ballooning in the slave hose but i believe this was like this for a couple weeks and I still have really good if not better clutch pedal feel now than I did before.
Post #965355 18th Sep 2022 7:28am
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 125
Australia 1998 Defender 110 300 Tdi SW Alpine White
Is the slave cylinder bleed nipple at the top?.
Post #966961 6th Oct 2022 11:39pm
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 125
Australia 1998 Defender 110 300 Tdi SW Alpine White
Dinnu wrote:
Your description sounds right.

Could it be you got a cheap fork and is bending under pressure? Perhaps that is the sound you are hearing?

Could you have spilled something on the clutch? Or it got wet?


Had a few engines whose friction plate stuck to flywheel due lack of use, but usually can break the bond by pressing the clutch pedal, put in gear, keep pedal pressed down and try to start the engine. It may damage starter, crash you in a wall or even worse so do at your own risk.


I've had this also, clutch in with first selected and a yank from a snatch strap, ride the clutch a bit once free and all good.
Post #966962 6th Oct 2022 11:54pm
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