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Peter Td4

Member Since: 23 Oct 2010
Location: Antwerp, Belgium
Posts: 228

2008 Defender 110 Puma 2.4 HCPU Santorini Black

Clutch pedal travel on Td5

Hi all,

I've replaced the clutch master cylinder on my Td5.

According to LR instructions the resting position of the pedal is about 140mm above the floor.
All is nicely purged, clear Dot4 fluid without air bubbles is flowing out at the slave cylinder.
The clutch works, however it bites only at the lower 20mm or so of the pedal.
This was also the case before I swapped the master cylinder and I was hoping to improve this.

What I notice however is the bolt on the underside of the pedal box that actually limits the clutch pedal travel.
This can be seen in the Microcat image as item 17.

Click image to enlarge

What is the correct procedure for setting this bolt

Can you guys with a Td5 check how deep you can actually press down your clutch pedal ?
Mine stops at about 2 - 2.5 cm from the bulkhead (so it could go quite a bit deeper).

On my Puma it actually goes much deeper, I have clearly more pedal travel on this vehicle.

All feedback / instructions / suggestions is much appreciated.
Thanks

. Peter,

Defender 110 StaWa - Td5
Defender 110 HCPU - Puma
Defender 90 Soft Top - Td5

31st Jan 2011 12:41pm

Peter Td4

Member Since: 23 Oct 2010
Location: Antwerp, Belgium
Posts: 228

Bump

Anyone got info on this

Peter,

Defender 110 StaWa - Td5
Defender 110 HCPU - Puma
Defender 90 Soft Top - Td5

1st Feb 2011 5:49pm

Lorryman100

Member Since: 01 Oct 2010
Location: Here
Posts: 2686

CLUTCH PEDAL AND MASTER CYLINDER ADJUSTMENT

1. The correct height for the clutch pedal from the floor of the footwell, without a mat, to the lower
edge of the pedal is 140mm (5.5in), dimension 'A'.

Adjusting
2. Withdraw the six screws and remove the top plate.
3. Slacken master cylinder push-rod locknuts to provide free movement of the push-rod through the pedal trunnion.
4. Slacken the adjustment screw locknut.
5. To increase the pedal height, turn the adjustment screw anti-clockwise. To reduce turn clockwise. When correct tighten the locknut.
6. To adjust the master cylinder push-rod, check that the push-rod has free-play through the trunnion.
7. Adjust the locknuts until the push-rod has 1,5 mm (0.062 in) free-play between the push-rod and
master cylinder. When correct tighten the locknuts.
8. Check that there is 6 mm (0.350 in) free movement of the pedal at the pad. If necessary readjust the push-rod.
9. Refit the top plate.

2nd Feb 2011 2:48pm

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