2012 2.2 Puma clutch issue

[Nomad9]

Hi There,
Jumped in the Deefer this morning drove to the shops, all normal, came out and went to some where else, short drive all appeared normal. Came out of the second shop gear stick wouldn't go into gear, pedal felt normal, nothing untoward. Pumped the pedal a couple of times still wouldn't go into gear.

Eventually had to stop the engine, engaged second gear and drove off, getting the revs right I could change gear. Came to stop, full drive engine stalled. Started again on the key, got to a junction to turn right clutch disengaged, put it into first and drove normally for a little while. Got home again stalled when I braked to stop.

Went into the house came out a drove normally up to the shed at the back, reversed into carport and stopped, then tried to get a gear to go forward...…….. no gears. Stopped the engine started it again and then got second easily, couldn't get any other gears. The pedal engagement when it works feels fine and engages drive where I would regard as normal.

119,000 klms 2.2 6 speed, has run perfectly until today usual rattly clutch which is on the menu to be fixed, just waiting for the parts.

Any ideas?

Thanks for any constructive information, greatly appreciated as usual.

Cheers Marty.

[justinc]

I suspect one of the damper springs has actually dropped out, jamming behind the diaphragm spring and preventing disengagement.

Jc

[Nomad9]

Hi JC,
Based on the assistance you have give me in the past no doubt you will be spot on. Fits with the symptoms. I've already bought the LOF upgraded clutch conversion kit getting ready to do the job, I was hoping it would be me making the choice about the timing rather than Jack Thank you very muchly.

While I've got your attention, whilst I've got the box out I was considering doing the Ashcroft output shaft conversion...………. is it worth it? Also do I have to take the exhaust pipe off to get the box out? (I've got a hoist [thumbsupbig]).

Cheers Marty

[justinc]

Hi mate , exhaust stays put, just remove the middle section. The Ashcroft coupling kit is a personal preference kind of thing. I fit standard ones and pack them with a decent Moly grease.

[spudfan]

Did you check the fluid level in the reservoir on the bulkhead? Such a sudden failure could be down to a loss of fluid. Most probably the springs as noted but check the fluid level...just in case.

[Nomad9]

Thanks Spudfan, master cylinder was my first port of call, and yes it was full, all good there. The clutch pedal felt normal and when it worked everything felt normal.

Cheers Marty

[DazzaTD5]

Hi There,


119,000 klms 2.2 6 speed,

Any ideas?


Cheers Marty.

Yerp, as JC said, tis the clutch, common common, search, there are at least two posts ref this just recently.

DEFENDER TDCI PUMA 2.4 2.2
CLUTCH KIT
LR068981 Adapter
LR068979 Cylinder - Clutch Slave
LR068982 Valve - Control
LR048731 SACHS CLUTCH ASSEMBLY

[DazzaTD5]

On that personal pref thing, I use the Ashcroft kit, especially now as the third gen kit the coupling is better manufactured over the standard poorly engineered Land Rover one.

Oh and while you are there you could decat the exhaust, very positive results. [biggrin]

[BilboBoggles]

Mine did this a few weeks ago. 2014 2.2 Puma. Had a new clutch 16 months ago. Just had the transfer case rebuilt twice! ... But ever since the clutch replacement a year ago, the clutch was very heavy and dull. The pedal always felt a bit rubbery, and you had to floor it to get it to disengage. I just figured it was due to a new clutch plate. I also noticed that the driveline would vibrate under heavy load at 1800 rpm.

Then a month or so I was away and my wife had a clutch failure to disengage with lots of noise. She managed to get it going, and slowly the noise went away. Well it turns out a spring had fallen out, and was jammed in the diaphragm. Now it drives like a new defender! Light easy clutch. No vibration.

So did the spring fail a year ago? No idea. But it's made such a difference to the NVH of that defender its like a different vehicle. So I think something was wrong from the start.

[Nomad9]

Thanks for the feedback interesting, which clutch have you got now? What brand was the “dull and heavy” clutch, do you recall? Sounds like everything is ok now it’s just a pity it took two goes to get there. Did you do anything with the output shaft on either occasion?
Cheers Marty

[Nomad9]

Hi There,
Took the gearbox out and found the spigot bearing had disintegrated, the rollers had fallen out of the bearing and were rolling around inside the clutch mechanism, from what I can see the bearing rollers were jamming on the outer diameter of the clutch plate and the flywheel. Springs were all loose and two of the small one in the centre had collapsed but hadn't fallen out. All the springs were still in place.

The two bolts coming from the engine side behind the exhaust and the block were a right royal PITA. LOF Clutches in the UK have been brilliant, I missed so parts of my list and they had the parts to me inside three days, great service. Anyway on with the rebuild now, one added bonus I found an Ashcroft output shaft upgrade kit had been fitted, all credit to the previous owner there.

Cheers Marty

[big harold]

Hi There,
Took the gearbox out and found the spigot bearing had disintegrated, the rollers had fallen out of the bearing and were rolling around inside the clutch mechanism, from what I can see the bearing rollers were jamming on the outer diameter of the clutch plate and the flywheel. Springs were all loose and two of the small one in the centre had collapsed but hadn't fallen out. All the springs were still in place.

The two bolts coming from the engine side behind the exhaust and the block were a right royal PITA. LOF Clutches in the UK have been brilliant, I missed so parts of my list and they had the parts to me inside three days, great service. Anyway on with the rebuild now, one added bonus I found an Ashcroft output shaft upgrade kit had been fitted, all credit to the previous owner there.

Cheers Marty
I have found 2 out of 3 had damaged the input shaft.
I made a spigot bush out of oil impregnated bronze.
Mark

[Nomad9]

Hi Mark,
Yeap I was in that place as well and had I not had the Deefer in bits and had known that the spigot bearing was rooted prior to taking the Deefer apart I would have made a bush out of Vespel CR-6100 which is a composite material with an element of carbon in it. It's used a lot at work very successfully in sort of similar but more arduous conditions. I could have had it made at work as well, had I had the time that's the way I would have gone most definitely.

Thank you for taking the time out to comment.

Cheers Marty.

[Shelby Ford]

New to this group as i'm juggling the idea of buying a Defender D90 YR 2012, found one with 70, 000KM & will be using it as the every day car, is this a good idea? thanks in advance :)

[DazzaTD5]

New to this group as i'm juggling the idea of buying a Defender D90 YR 2012, found one with 70, 000KM & will be using it as the every day car, is this a good idea? thanks in advance :)

I would suggest you make a new thread along the lines of "thinking of buying a 2012 Defender classic" rather than adding to an old thread from back in 2019

You will get far more responses