Thread: TD5 - clutch mystery problem

Hi

I had a problem with my clutch initially loosing ability to change gears I did notice (afterwards) that the master cylinder had run dry. I had ordered parts and as i did not know the service history of the car decided to go all out and give it a birthday.....

So far i have changed the clutch, Master cylinder and slave cylinder. I have reverse bled, gravity bled and normal foot pumping twice and can not see any air bubbles at all.

The clutch pedal when pressed has small free play before you can feel the clutch starting to disengage.......the problem is that it feels like it just need's that little bit more distance to travel.

The clutch Pedal stop bolt is wound out so the pedal hits the floor and the master cylinder push rod is at its maximum adjustment (to give it the fullest range of travel).

The friction disk is in the correct way, spigot lubricated, the fork was tied with a zip/cable tie and all moved as it should before i put it back together.

I have felt the flexible bit of a the pipe and can not feel any ballooning when the peddle is pressed but can feel fluid passing as usual.

Engine off -The gears can be selected no problem at all
Engine Running LOW - can select although not easy
Engine Running High ? harder to get in to gear -

I have managed to get it in all gears with a bit of persuasion and have managed to drive it a very short distance.

I was wondering weather I had the right combination of master / slave cylinders and have put on the following which all seem correct
Master cylinder STC 500 100
Slave cylinder FTC 5202
Clutch britpart TD5

The only thing i can think of now is trying to stick a borescope inside. Apart from that i am running out of ideas and really could do with some pointers. Am ready to strip it down again to see if i have missed something?? but was wondering if any one has come across this before.

did you set the pedal - mc pushrod freeplay?