Defender Clutch Pedal...........

[jerryd]

I recently changed the gearbox / transfer case and put a brand new clutch kit in my 300 tdi defender. All was fine for about a week when the clutch pedal went a bit limp. It seems to have about 70mm of nothing from the top of the pedal before the clutch bites. The actual pedal travel from the floor to the play is probably 30 mm.

Could this be the slave cylinder or master cylinder worn out ?? Is there any adjustment on the pedal ??

Thanks in advance for any diagnosis

[rick130]

There's an adjustable pushrod that pushes the piston in the M/C.
The locknut on this may come loose but usually it goes the other way and you have clutch slip.

It would more than likely be the M/C itself, mine did exactly the same thing a bit over a week ago as I was taking it off the road to do the t/case.

I've bought a new 3/4" bore M/C as I reckon that's what's happened to mine, will find out on the weekend when I get back into it. (and hopefully the new gears turn up )

[stealth]

I had a new master cylinder fitted a few thousand kms ago which started doing what you described. Then it came good. It was suggested a bit of muck in the master cylinder may have been fouling the seal. Still monitoring it but problem hasn't returned.

[rick130]

I had a new master cylinder fitted a few thousand kms ago which started doing what you described. Then it came good. It was suggested a bit of muck in the master cylinder may have been fouling the seal. Still monitoring it but problem hasn't returned.

Yep, it's the piston not returning in the m/c, either wear in the bore (which is possibly my case) or a bit of muck in the bore or muck in the return port.

[jerryd]

The clutch pedal is about 25mm lower than the brake pedal so I'm just going to try and adjust it. Just found the chapter in my handbook so I'll report back later.