Slipping clutch

[Leyland1980]

I have a 2004 TD5 110 Double cab.

In recent months I have noticed a little bit of clutch slip on hard acceleration/heavy load (laden climbing hills etc no towing).

It has ~204,000km on the clock and had a new clutch plate and DMF at ~160,000km (about 3 years ago).

~45,000km seems low to me for clutch failing due to wear but is there anything else it could be? Some adjustment that can be done?

Cheers

John

[JDNSW]

There is no adjustment. There is a slight chance that there is a hydraulic problem causing this, but if there is free play on the pedal, this is very unlikely.

Most likely cause, other than wear, is oil contamination, either from the rear crankshaft seal or from the front gearbox seal or possibly other ways of getting gearbox oil out.

To check this, remove the wading plug (if fitted). If this gives you more than a few teaspoons of oil, then you can be reasonably sure that this is the problem. The colour of the oil will usually tell you whether it came from the engine or gearbox.

[Leyland1980]

If it is oil contam I assume that its GB out, replace defective seal/seals new clutch plate and all back together.

[JDNSW]

If it is oil contam I assume that its GB out, replace defective seal/seals new clutch plate and all back together.

Yes, although it may be a toss-up whether engine out or gearbox out is easier. Probably depends on what gear you have and your working space. I have done both, and am still undecided which is easier. Neither is real fun!

John

[Gillie]

I have just done mine. New clutch and dual mass fly wheel on a 2000 td5 defender. I tossed up either the engine of gearbox and was told the engine is a lot more work. I did it in the garage by myself amongst other jobs and took my time. It took about 5 days just grinding through it. Not much fun but either is having the clutch slipping.
The worst part was the 15 mm bolt on the starter and the two bolts at the top of the tunnel. Getting those back in required some patience. The bolts holding the rear propshaft to the handbrake drum decided to round off inside the drum making for some interesting angle grinding.