TD5 Cltuch problem HELP

[Bauke]

Vehicle Details

2000 td5 defender
disco transfer case
255-85-16 tyres
chipped
larger intercoller

here is the problem replaced the clutch and flywheel and rebuilt the gearbox, all going well till i put a chip in it now the clutch has started to slip in the last few weeks and especially when i put the intercooler in, have checke dfree play etc in clutch all okay so i removed the slave cylinder and took it for a run without the clutch no probs not slipping at all, so i removed that great big spring from the slave cylinder as this pushs on the preasure plate quite hard this has helped a lot but i can still get it to slip when pulling hard in 3 and 4 gear

any thoughts on the problem or does the clutch have to come out to check for faults

[Allan]

Check the master cyl. settings.

Allan

[Jock The Rock]

Check the condition of the bore of both the slave and master cylinders

I had a similar problem and it turned to be the slave cylinder piston not returning straight away (because the slave cylinder was scored and leaking) which produced a clutch slippage problem after changing gears

[Bauke]

master cylinder must be okay as i can push th slave cylinder all th way back in which means the master cylinder is returning far enough for the resevoir to be open and theres plenty of free play at the pedal