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Thread: Clutch failure within a few days of being installed (Holden 202 engine)

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    Clutch failure within a few days of being installed (Holden 202 engine)

    Hi guys,

    So I recently finished my complete rebuild of a Series 2a with a Holden red 202 in it (and holden clutch/pressure plate). I got it registered and drove it for a few days before the Clutch just completely died, I couldnt push the pedal in other than the smal;l amount of free play. I read a few other threads and it seemed like it might have been a clutch fork or similar issue, so I pulled the gearbox back out, had a look at the clutch fork and it seemed to be operating completely fine, could slide back and forth easily etc. I also checked the Slave Cylinder (pressing on the pedal with it unattached) and that seemed to be working too, or at least the part that pushes the push rod was moving. So i took the clutch pressure plate off and reinstalled it thinking I may have done something wrong there. After I reinstalled it I am still getting the same issue, any recommendations on what to try next? I have been thinking maybe its just a faulty Clutch assembly but I dont want to buy a whole new one if thats not the issue.

    Thankyou!

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    sounds like another recent series rebuild on here , he had no end of trouble getting it right

    I cant think of his name , maybe someone can enlighten.....

  3. #3
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    If you take the pressure plate & Clutch plate to a clutch specialist they will be able to test it for you .

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    some photos would be helpful,
    i"ll put my money on it being a hydraulic issue ,
    before you disassembled did you release the bleed nipple on slave cyl and try to push clutch pedal ?

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    JDNSW is offline RoverLord Silver Subscriber
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    I agree. First suspect, blocked hydraulic line, then master cylinder. Is it the 2a setup or does it have a Series 3 box, your comment about the fork suggest it could be?
    John

    JDNSW
    1986 110 County 3.9 diesel
    1970 2a 109 2.25 petrol

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    Quote Originally Posted by goingbush View Post
    i"ll put my money on it being a hydraulic issue ,
    before you disassembled did you release the bleed nipple on slave cyl and try to push clutch pedal ?
    Hey goingbush,
    Yes I did try that one, when i released the bleed nipple the pedal was able to go to the floor easily. I believe that means that the issue is after the slave cylinder, is that correct?

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    Quote Originally Posted by JDNSW View Post
    Is it the 2a setup or does it have a Series 3 box, your comment about the fork suggest it could be?
    Hi JNSW,
    Yes sorry I forgot to mention that, it is a very late series 2a so has the series 3 gearbox in it not the standard 2a box.

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    Quote Originally Posted by Harro_9 View Post
    Hey goingbush,
    Yes I did try that one, when i released the bleed nipple the pedal was able to go to the floor easily. I believe that means that the issue is after the slave cylinder, is that correct?
    yes, I would have thought that test reduces the chance of fault being hydraulic .

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    JDNSW's Avatar
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    If you remove the gear lever support and look through the inspection opening, it is possible you may be able to see what is going on.
    John

    JDNSW
    1986 110 County 3.9 diesel
    1970 2a 109 2.25 petrol

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    Quote Originally Posted by JDNSW View Post
    If you remove the gear lever support and look through the inspection opening, it is possible you may be able to see what is going on.
    That was a great idea, can't believe I hadn't thought of it!

    I had a look and it appears that the release bearing is relatively tight up against the pressure plate (see pic) and it moves in maybe 5-10mm when i push the pedal down (pedal is able to go in a small amount, maybe 5cm). after the 5 or so cm the pedal wont go in any further and the clutch is still not disengaged. Checked by trying to spin the rear propshaft whilst in gear. I think that all this means that the clutch/pressure plate are faulty and need replacing?
    2022-03-22 19.48.41.jpg

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