Thread: D2 Clutch Life...

Clutch life with any manual transmission is almost totally unpredictable, because the biggest single factor is driving technique, followed by the type of driving. All anyone can do is say what mileage they got, but it is anyone's guess whether you will get anything like that.

John

My advice with a D2 without CDL, is get it operational ASAP if using it in sand, ESPECIALLY towing. This is one thing that will kill the clutch early, traction control operation in sand. I have recently replace 3 clutches in D2's, none less than 180K, the highest mileage one 288K. The 180K one had been bogged on a beach more than once towing a boat.
The D2 clutch is way bigger than the Tdi one and IMHO more robust in construction and consequently lasts longer. Also, the clutch fork is the same as the V8 cast iron type so no issues with punching the pivot through prematurely.

Sounds like you are conscious of looking after the clutch etc by using lowrange at times so I would say there isn't any likelihood of it needing replacement anytime soon

I would again urge you to fit a CDL kit.

JC

I would also replace the dual mass flywheel at the same time.They are only good for 200/250k depending on abuse recieved.Mine has been complaining(noisy till warm and the odd shudder) for 45000ks(245000K) and is up for replacement in the new year with a new clutch.
Andrew

Thanks very much fellas. Yep I am careful with it and never ride it or let it out too slowly unless towing the boat up hill, but then if the hill is too steep I usually use low range.

Its a V8, so is it the same clutch flywheel set up as the TD5?

Cheers and thanks.

A timely question Ozscott, I was just going to ask the same thing. I have a 2004 TD5 manual with on 89k on the clock. Clutch comes in early as normal but takeup has been getting progressively longer. I have only a small freeplay after the take up. This does change depending on the hill slope and loading. I am assuming the clutch is getting near the end of its life but am not sure how long I've got.

I've always had manuals and considered myself to be very easy on clutches. The life on this one is very disappointing, as I would have expected 150k to 200k. My question was, are there clutch options? That is, are there standard and heavy duty options and if so, what are the issues and costs relativities?

Mundy

There was a recall on the Valeo clutch on earlier D2s, so you may have a relatively new clutch.
I pulled mine at 190 because of a growling spiggot bush to find I had more than 3/4 life left.
Agree 100% that it depends on driving style and type of driving. ie City / country.

The boys D2 was exhibiting classic symptoms of a clutch on its last. After pulling it we found more than half left in it, but severe wear on the pressure plate fingers from th thrust bearing not disengaging fully.

More investigation found the master cylinder with damaged spring and jamming. This gave the impression of the clutch failing.

Cheers

Originally Posted by ozscott

Thanks very much fellas. Yep I am careful with it and never ride it or let it out too slowly unless towing the boat up hill, but then if the hill is too steep I usually use low range.

Its a V8, so is it the same clutch flywheel set up as the TD5?

Cheers and thanks.

Ahh, for some reason I thought it was td5

In that case, no I have never had to replace a V8 clutch yet in a D2. They are a good long lasting unit and quite big/ heavy duty. There is no dual mass flywheel with the V8 thank goodness, makes for a way cheaper clutch kit
Still go the CDL kit though.

JC

Thanks JC matey!

Cheers