 | Home > Puma (Tdci) > How do you replace the 2.2 clutch master? |
 
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20749  
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Cut the soundproofing away from the MC bolts, it is reachable from the footwell up IIRC.
It is a very awkward angle though, so be sure not to do your back a mischief as an example in that process. You can use a blade to cut around the bolt / nut carefully, the soundproofing stuff should come away then, just don’t cut too deep into the paint behind, with s bit of skill you can take it off like that. Ratchet spanner and socket set is likely useful. Is there a reason you are replacing it? WeWillWin🇬🇧🇺🇸 ⛽️🛢️⚙️🧰💪 |
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18th Apr 2025 5:11pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2262
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You can change the master cylinder without pedal box removal. No cutting, no damage, circa 2 hours, will need a helper for 15 mins.
See https://www.defender2.net/forum/topic71892...p;start=30 |
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18th Apr 2025 8:01pm |
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| itsdashy Member Since: 20 May 2021 Location: Reading Posts: 75 
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Ah, my problem is they were too liberal with the black sealant and they encapsulated the lower master cylinder nut in it. (in the engine bay) The standard insitu guide won't work as I cannot get a socket, spanner etc onto it as its covered.
Can you remove the pedal box without removing the brake lines on a 2.2? |
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18th Apr 2025 9:09pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2262
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Sorry, I misunderstood which nut you were referring to. That’s the first time I’ve heard of that nut getting covered in sealant.
I think the pipes will need removing and relocating, the fact they ran them over the top of the MC , when with a little more thought and effort they could have run them around the MC, is shocking! Have you tried to see if a 10mm ratchet spanner within the footwell will loosen the bolt ? Perhaps all the sealant will hold the lower MC nut in place. Else it may break the sealant loose off the lower MC nut so you can get a spanner on it. I used a Halfords advanced 10mm ratchet spanner that is small enough to fit and allows a few clicks of movement each time. |
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18th Apr 2025 10:16pm |
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| itsdashy Member Since: 20 May 2021 Location: Reading Posts: 75
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Funnily enough I have the same ratchet spanner. I shall give it a go tomorrow
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18th Apr 2025 10:31pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2262
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It’s a real fiddly job getting to the bolt via the footwell. You end up on your back/ side in the footwell, trying to get the ratchet spanner on the bolt in the box with very little room for manoeuvre.
If you happen to be a combination of a contortionist and a gynaecologist you will be fine  else like me you will end up having to take a few breaks to scream at the moon and stretch off the cramps. |
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18th Apr 2025 10:41pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20749
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Yes, this is so true, I used a Wera Joker spanner for the very reason, as it has very little movement on the ratchet needed to gain some torque on the fixing. Annoyingly I didn’t have the slightly offset Switch type, so that made it that bit more tricky to do. It isn’t a fun job that’s for sure, I’m glad it’s only one that is needed rarely. In my case I need event have bothered, but when the MC was many years old it could pack up at any time, but overall are very reliable, which is more than can be said for the slave. The pedal box I think you can get out, but only in a certain way, whether that is only with the MC taken off first I can’t quite remember. I do know those fixings I put a little anti seize on, so that in future it’d not be an issue. Soundproofing junk in that area though is just bad practice, knowing its parts that are needing access. Personally I didn’t fit any sound proofing on that area behind the dash, I don’t think a lot can realistically be done with it. WeWillWin🇬🇧🇺🇸 ⛽️🛢️⚙️🧰💪 |
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19th Apr 2025 2:18pm |
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