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Caterham

Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6308

2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey

sorry - spotted you'd replace the slave but missed the master cylinder.

1st Apr 2016 1:37pm

Happyoldgit

Member Since: 14 Sep 2007
Location: Norfolk
Posts: 3471

2015 Defender 110 Puma 2.2 USW Corris Grey

Grenadier wrote:
Mine is the first Defender he has touched. Are they that much harder?

No, as long as he knows what to check and has the correct parts the basics are the same. With a decent selection of tools [including a clutch alignment tool] and some common sense a willing and competent novice should be able to tackle the job. Steve.
Owned numerous Land Rover vehicles of all shapes and sizes over the decades.
Current Defender: A non tarts hand-bagged Puma 110 XS USW.

[Insert something impressive here such as extensive list of previous Land Rovers or examples of your prestigeous and expensive items, trinkets, houses, bikes, vehicles etc]

http://forums.lr4x4.com

I used to be Miserable ...but now I'm ecstatic.

1st Apr 2016 2:19pm

Grenadier

Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5850

2011 Defender 110 Puma 2.4 DCPU Corris Grey

Thanks new and improved HOG

Just out of interest, how vital is the clutch alignment tool? He did use a tool, although seemed to be a creation rather than purpose built. Can this lead to the woes I have described above? Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

2nd Apr 2016 9:52am

Grenadier

Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5850

Devon-Rover wrote:
Hi for the sake of repetition i'll fire some number at you.

Clutch kit LR048731 Earlier engines all supersede to the later ones.

The Clutch hydraulics did have a change and this impacts on the bits used, so if you have a new slave/release bearing for the first time then you need a couple other bits to go with them.

LR068979 is the slave cylinder and when you use this one for the first time you must then use:

LR068981 Adaptor
and
Lr068982 Valve

These two part go with the new release bearing or issues could occur.

The Spigot bearing is indeed a bearing and should be ok with a tickle of grease. but normal caveat says to check for wear or roughness.

Have checked, apart from the Spigot, all is as you gave listed and what's more (bar the clutch being AP but coming from Ashcroft) all are OE. As mentioned with HOG above, I have not done the spigot.

However, I'm still unclear if there is a difference between the 2.2 and 2.4 friction plate and cover or if they're one and the same? Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

2nd Apr 2016 10:02am

uncas

Member Since: 22 Nov 2012
Location: Wentworth near Rotherham
Posts: 340

With regards to the clutch alignment tool I've used a length of bar with masking tape on before on cars I've still got a gasket hammer with splines on the end of the shaft from using that for aligning a clutch and I've also aligned the clutch up by eye on heavy dump trucks (needs must when you're in a quarry and have to get the truck back on the road) I'd be tempted to slacken all the mounting bolts for the gearbox including the rear mounting and giving the starter a spin over with someone sitting in the cab with the clutch pedal depressed just in case there is a slight misalignment. If that doesn't work then it's pull the gearbox time. I always used to lightly lubricate the spigot shaft and bearing before assembly.

2nd Apr 2016 10:43am

Happyoldgit

Member Since: 14 Sep 2007
Location: Norfolk
Posts: 3471

What he says ^^^

I've done them by eye in the past too, and using lengths of dowel wrapped in tape as well as the usual using an old input shaft. If the shaft goes through the plate easily then the alignment will be ok. General clutch alignment tools with a variety of adapters for different plate and spigot bearing sizes can be got quite cheaply and give you a sense of security knowing you can tackle a variety of vehicles should the need arise Steve.
Owned numerous Land Rover vehicles of all shapes and sizes over the decades.
Current Defender: A non tarts hand-bagged Puma 110 XS USW.

[Insert something impressive here such as extensive list of previous Land Rovers or examples of your prestigeous and expensive items, trinkets, houses, bikes, vehicles etc]

http://forums.lr4x4.com

I used to be Miserable ...but now I'm ecstatic.

2nd Apr 2016 2:55pm

Wild Card 90

Member Since: 03 Dec 2014
Location: Gerlingen
Posts: 1060

2012 Defender 90 Puma 2.2 SW Indus Silver

Grenadier, I cannot believe the hassle you're having with a clutch. My sympathy! Lots of good knowledge and experience coming to your rescue, here. D2net

As already said, alignment and the right parts are the most likely areas to check up on. A clutch plate that has been shipped from the UK to Switzeland may well have had a knock or two on the way, and only needs to be slightly warped. However, that should be visible on assembly.
Silly question - have you made any other changes like rubber mats or soundproofing in the footwell? The standard Defender rubber mat already touches the fully depressed clutch pedal. Cruise control - clutch pedal switch? Unlikely as you are planning to swap your vehicle soon, but thought I'd ask. 1998 Tdi 90 SW,
2008 Td4 90 SW,
2012 2.2 90 SW,
2" raised Trailmaster/Terrafirma
Heavy Track Raids, 255 MT´s,
Recaro CS´s, anorak, wellingtons

2nd Apr 2016 4:01pm

Happyoldgit

Member Since: 14 Sep 2007
Location: Norfolk
Posts: 3471

I admit to not having read the complete saga but if you changed the master cylinder have you checked that the pushrod setting is correct so that you are getting the appropriate amount of travel? Steve.
Owned numerous Land Rover vehicles of all shapes and sizes over the decades.
Current Defender: A non tarts hand-bagged Puma 110 XS USW.

[Insert something impressive here such as extensive list of previous Land Rovers or examples of your prestigeous and expensive items, trinkets, houses, bikes, vehicles etc]

http://forums.lr4x4.com

I used to be Miserable ...but now I'm ecstatic.

2nd Apr 2016 4:31pm

Cetane

Member Since: 27 Nov 2012
Location: Lancashire
Posts: 171

2010 Defender 110 Puma 2.4 HT Galway Green

You got the problem sorted yet mate?

7th Apr 2016 10:24am

Grenadier

Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5850

Nope. The mech gave our local indie a buzz and he thinks, assuming the mech is telling him the truth and what's actually going on, that the friction plate is the wrong one. Too thin. Not sure if that's possible? Anyone know if there are any differences between a 2.2, 2.4, perhaps tdi, that would allow the plate to be too thin yet still be fitted? Anyway, it's going to be dragged down the hill and opened up for a third time.

The buyer is being super patient.... Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

8th Apr 2016 6:24am

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

2013 Defender 110 Puma 2.2 XS DCPU Keswick Green

Well good luck with that.

If the friction plate is too thin then surely it would be less likely to drag rather than more likely?

8th Apr 2016 8:42am

Cetane

Member Since: 27 Nov 2012
Location: Lancashire
Posts: 171

These images are from a copy of Microcat kindly hosted by a forum user.

It shows a difference in clutch mounting bolt depth for 2012-> also the WSM manual says they must be replaced along with clutch. Cant think how it would create your problems, but a perhaps something else to investigate?

Click image to enlarge

Click image to enlarge

Edited to fix a pic.

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

Last edited by Cetane on 8th Apr 2016 9:36am. Edited 1 time in total

8th Apr 2016 9:24am

Grenadier

Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5850

Thanks Cetane. Anything will help. An ever increasing part of me thinks it's just the mech I have used is a bit useless....Hope the chap down the hill, the porfessed Defender nut I have posted about previously, will spot the problem and get is resolved sharpish. If not, strip and reassemble....

Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

8th Apr 2016 9:32am

ericvv

Member Since: 02 Jun 2011
Location: Near the Jet d'Eau
Posts: 5816

2009 Defender 110 Puma 2.4 SVX Station Wagon Santorini Black

Believe in Sallanches there are three Land Rover specialists. One of them regularly gets mentioned in the french Land Mag magazine. Might be worth to check around about this.
Eric You never actually own a Defender. You merely look after it for the next generation.
http://youtu.be/yVRlSsJwD0o
https://youtu.be/vmPr3oTHndg
https://www.youtube.com/watch?v=_GtzTT9Pdl0
https://www.youtube.com/watch?v=ABqKPz28e6A
https://www.youtube.com/watch?v=rLZ49Jce_n0
https://www.youtube.com/watch?v=XvAsz_ilQYU
https://www.youtube.com/watch?v=K8tMHiX9lSw
https://m.youtube.com/watch?v=dxwjPuHIV7I
https://vimeo.com/201482507
https://www.youtube.com/watch?v=ZSixqL0iyHw

8th Apr 2016 11:27am

Grenadier

Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5850

Merci Eric,

Used to be three, the 'dealer' has changed to 'Subaru'. However the guy who provided the advice mentioned above is the one you're thinking of, AccroLand. You can see his passion in my thread 'Defender Love'. Nice guy. Only reason I didn't go to him in the first place is that he was booked until end of April and the Defender was supposed to be sold a week ago. Fortunately that has been delayed at least until May.

By the way Eric, did you get your poster? If not, I have a copy (unopened) if you want one or an extra one, given you are actually on the collage. PM an address if you're interested and I'll pop it in the post.

Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

8th Apr 2016 11:32am

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