Thread: Disco Clutch

recently i took my TDi disco in to the the mechanics to get my clutch master cylinder and slave done as i thought they had "gone" on me when down the Gold Coast, drove it home no worries.
when the mechanics took it for a test drive after the installment of the clutch cylinders the clutch stopped working, aha we thought it must be the clutch fork so out come the gearbox and no the clutch fork is fine (although not modified) but the clutch throw-out bearing CARRIER was MELTED yep melted as it was plastic!!!!!, the mechanic was astounded nearly as much as i was, so new clutch kit, modified the fork and reinstall the gearbox, all good so far

you can buy heavy duty kits with all that stuff already done. i just did mine. although i used another plastic thrust bearing. id say melted probably due to bearings being shot as mario said. my old clutch was in bad shape and flywheel and pressure plate were burnt and very worn although the plastic bearing was still in ok shape.

you can weld bit of metal to fork at pivot or just buy a new HD fork with it already done. which is what i did. not much more expensive. valeo clutches are generally pretty good. although the pressure plate bolts are hard to get to. had to buy a skinny socket and grind down the edges a bit to get to them properly.