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Mark-Eran



Member Since: 11 Dec 2011
Location: Durban
Posts: 8

South Africa 
Weird clutch problem...
Hi,

I am running a Defender 110 "Puma" 2008 with the Ford Engine 2.4 l -
I have got a weird "clutch" problem which is baffling even the dealer!

On a long stretch of road (let's say on a freeway, running continuously in sixth gear around 110-120 km/hr for a least 100 - 150 km) I have got a blockage of the gearbox and cannot downgrade from 6th to 5th or other lower gears.
Related (or unrelated?) my clutch pedal becomes all soft (it does come back however slowly but all the pressure is gone)

Stopping the car and forcing the gear into neutral, I just need to wait a few minutes to have full control again with the clutch pedal totally normal and the gearbox smooth in any gear...
This ONLY happens on long stretch of road when I do not use the gearbox, set to the highest sixth gear position - It never happens on short distances -
Furthermore I do not have any clutch fluid leaking anywhere.

We checked the clutch fluid and found it a bit dirty which might indicate that the seals of the master-clutch cylinder might be damaged and that it needs to be changed. This is easy but what worries me is that it might be the slave cylinder causing this problem which would be a totally different problem as I believe it is inside the gearbox.
Still, all this does not explain why a sudden loss of clutch when I drive constantly in 6th gear for a long period might totally fix itself after a few minutes once I stop down...
Any idea and has any Puma Ford engine owner with a six gear gearbox experienced this kind of problem?
All the Best
Mark
Post #264837 9th Sep 2013 1:06pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17414

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
The clutch slave cylinder is in the bellhousing (clutch housing, between engine and gearbox), and accessing it involves removing the gearbox, which isn't actually as difficult as it sounds provided that suitable (ie main dealer) lifting and access equipment is avaiable.

My first suspicion from your description and location is that it is heat related. 5th gear on the MT82 box is direct, whilst 6th is an overdrive, and the box will generate more heat running in 6th than 5th. I suppose that it is just possible that the heat is causing moisture in the clutch fluid to boil, thus losing the pedal, but even so I would expect you to be able to change gear without using the clutch. From the description you have given, it sounds as though the gear lever becomes immobile (so possibly the lever, selectors or dog clutches themselves are seizing) rather than it simply being a clutch related problem.

Not much help, I'm afraid! Perhaps someone else will chip in with some ideas.
Post #264848 9th Sep 2013 1:41pm
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dilukabey



Member Since: 17 May 2011
Location: Sri Lanka
Posts: 173

2009 Defender 110 Puma 2.4 SW Keswick Green
May be your clutch is worn off or check the quality/ level of gear box oil. Very Happy
Post #264856 9th Sep 2013 2:11pm
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dilukabey



Member Since: 17 May 2011
Location: Sri Lanka
Posts: 173

2009 Defender 110 Puma 2.4 SW Keswick Green
May be your clutch is worn off or check the quality/ level of gear box oil. Very Happy
Post #264857 9th Sep 2013 2:12pm
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dilukabey



Member Since: 17 May 2011
Location: Sri Lanka
Posts: 173

2009 Defender 110 Puma 2.4 SW Keswick Green
May be your clutch is worn off or check the quality/ level of gear box oil. Very Happy
Post #264859 9th Sep 2013 2:21pm
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spudfan



Member Since: 10 Sep 2007
Location: Co Donegal
Posts: 4677

Ireland 
If the gearbox has been filled to the level plug it is overfull. This has been stated to cause overheating in the gearbox. Whether this would cause your problem or not is not clear.The gearbox should have 2.4l of the correct oil from the factory and 2.2 l after a service drain and refill. You can access the filler plug by removing the centre tray or cubby box then the inspection plate. If the gearbox is full to the level of the filler plug it has too much gearbox oil in it. To remedy this, just drain it and put in 2.2l. I refilled mine via the inspection plate using a length of hose and a funnel. You could try the above to see if that helps.Just make sure it has the correct spec oil in the gearbox.
I used Total Transmission Syn FE 75w90 in the gearbox
in my 2008 Puma and it runs beautifully. 1982 88" 2.25 diesel
1992 110 200tdi csw -Zikali
2008 110 2.4 tdci csw-Zulu
2011 110 2.4 tdci csw-Masai
Post #265010 9th Sep 2013 9:56pm
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robharvey



Member Since: 14 Dec 2009
Location: Durban
Posts: 86

South Africa 2009 Defender 110 Puma 2.4 SW Alpine White
Mark, which dealer?

Have you tried Paul Close at The Centre? 031-3378521, he's way more clued up on Defenders than the dealers are.
Post #265104 10th Sep 2013 9:07am
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Mark-Eran



Member Since: 11 Dec 2011
Location: Durban
Posts: 8

South Africa 
Hi Rob,

Don't worry I don't use Landy dealers anymore : far too expensive and often not as knowledgeable than a few specialised individuals around. Furthermore my 2008 Puma is now out of guarantee.
I use a very good guy in Pinetown : his name is Russell and available on 0723232013 - For TD5 he is the best guy around and is on a learning curve with the Puma! But I trust him and I suppose this is nowadays the most important.
Post #265110 10th Sep 2013 9:25am
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RafaBr



Member Since: 29 Oct 2013
Location: Curitiba
Posts: 3

Brazil 
Hi Mark,

Did you fixed this issue with the Clutch?
I'm having the same problems after a long period in 6th gear (1 hour in hot conditions). After some pumps it works normally.

Regards

Rafael
Post #277688 29th Oct 2013 7:37am
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Mark-Eran



Member Since: 11 Dec 2011
Location: Durban
Posts: 8

South Africa 
Hi Rafael,

Impossible to say yet.
I have replaced the master clutch cylinder (a telltale sign was that the DOT4 clutch was dirty probably due to the breakdown of its seals) and also bleeded and replaced the clutch fluid)
This was the easiest and cheapest part as the replacement of the slave cylinder would require a drop of the gearbox, change of seals... a more involved and costly job.
Until now I have not had the opportunity to go for a long drive. I believe that it is definitely connected to high temperature (my driver seat metal fixations and hand break become extremely hot during long drives taking place in hot weather)
Some time ago I had the opportunity to drive 600 km by cool weather = no problem! The same return drive by hot weather brought a loss of clutch, the time to stop over, wait for the engine temperature to cool down a bit, pump a few times the clutch pedal and everything was fine again...
But this was before I changed the master clutch cylinder and renewed the DOT4 fluid. So let's hope that the problem was connected to the master clutch cylinder seals breakdown...
All the Best
Mark
Post #277721 29th Oct 2013 10:13am
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