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lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

Clutch adjustment?

Well, clutch pedal adjustment on my TD5.

The clutch biting point is a bit low. I have bled the hydraulics and adjusted the low stop screw. But the pedal at rest is about 1cm too low.

Trouble is, l can’t shift the two lock nuts on the master cylinder rod to adjust it. None of my spanners will fit (or if they do, you can’t turn them)
I was told to try it with the pedal pressed down, but l still can’t get a spanner on the inner nut, it’s also narrow so the spanner is too big.
What’s the solution?
Is there a special narrow/slimline spanner or do l have to make one?

Last edited by lightning on 8th Feb 2019 1:42pm. Edited 1 time in total

8th Feb 2019 12:28pm

Mo Murphy

Member Since: 01 Jun 2008
Location: Letchworth Garden City, Herts
Posts: 2244

1984 Defender 90 BMW M57 3.0 Diesel HT Auto Pennine Grey

Make one, requires the sacrifice of a spanner. Once made you have it forever or until you lose it 😉
Mo The Land Rover 90 - Many are called, few are chosen.

50 Shades of Pennine Grey

8th Feb 2019 12:50pm

4RF RDS

Member Since: 19 Jul 2015
Location: Ottawa
Posts: 940

2000 Defender 110 Td5 XS CSW Epsom Green

Clamp a pair of needle nose vise grip pliers (mole grip I think you guys call them) on the threaded shaft and use a wrench on nut.

Click image to enlarge 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)

8th Feb 2019 3:09pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

That’s an idea, thanks l will give it a try.

Also l have ordered two spanners to see if l can cut them down to fit.

8th Feb 2019 4:08pm

Procta

Member Since: 03 Dec 2016
Location: Sunderland
Posts: 5183

lighten check your master cylinder for leaks too, just in case. My dads had a problem. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

Success is 90% Inspiration and 4 minutes Preparation # you can make it!

8th Feb 2019 6:51pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

Can anybody tell me if a TDCi clutch pedal box/master cylinder is the same as a TD5 one?

10th Feb 2019 5:34pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

I can answer this as l have just fitted one.

Yes it will fit in place of a TD5 assembly, one mounting hole is in the wrong place but you can either leave it with five bolts or drill an extra hole.

The clutch switch is different on the TDCi. Although it looks the same, it’s a normally open switch where the TD5 one is normally closed.
So you also need to swap it with your TD5 switch, a very easy job which takes a couple of minutes.

After 100,000 miles the pedal mechanism had some play in it so now the clutch action is better, with less play before anything happens.
Plus the TDCi pedal has the assist spring already fitted and this makes for a lighter clutch action.

17th Feb 2019 4:23pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

I also figured out a way to get to the locknuts on the master cylinder rod without modifying spanners to fit.

Wedge the clutch pedal down.
Loosen the nyloc nut on the end of the master cylinder rod until it’s as far off the end as possible without falling off.
Release the clutch pedal.
The clutch pedal arm will end up against the nyloc nut, leaving the two locknuts clear of the arm and accessible with ordinary spanners.

19th Feb 2019 10:28am

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

OK so l have loosened the locknuts

Can someone tell me the correct resting position of the clutch pedal? The service manual says that the bottom of the pedal should be 140mm from the floor.
But it doesn’t say whether that is with or without the pedal rubber fitted.

23rd Feb 2019 7:46pm

4RF RDS

Member Since: 19 Jul 2015
Location: Ottawa
Posts: 940

With... to bottom edge of pedal.

2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)

23rd Feb 2019 8:42pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2840

Thank you.

24th Feb 2019 9:30am

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