Clutch Pedal to the Floor 2.4 Puma

[Chenz]

Coming home from a long drive last week I noticed a couple of times when engaging the clutch to select 1st gear the vehicle lurched forward slightly.

Got home parked up and this afternoon went out to turn the old girl around, started it and pushed the clutch in - pedal to the floor where it stayed.

Can pull it back by hand but same again. Checked clutch fluid level - no fluid.

Now have had problems like this in my old 200 Tdi so thought slave cylinder and jumped under to check it out. Now where the hell is it on the Puma?

Checked the workshop manual and see it is on the side of the gearbox but I cannot see it from above or below.

Anyone with any experience in how you get at it to change it if this is indeed the problem.

Any help would be appreciated

[Chops]

Its inside the bell housing. Stupid place to put it as of course, you'll need to remove the gearbox to get at it.

[rangieman]

Its a Defender it will be the M/C more than likely

[Chenz]

MC looks fine, no leakage there but at the bottom of the bell housing there is a smear of fluid which looks and smells like Dot 4 fluid.

Why would they put the slave cylinder inside the bell housing??????? Dumb dumb dumb

[Chops]

And really dumb some more.

Chris and I replaced my MC as it was giving a bit of grief, check the colour of your fluid, that'll tell you which end the problems at. If it's dirty in the MC, get a new one, flush your line right out and see how it is.
I think from memory a new unit cost me $30-40 (?) and the bonus was being able to fix my squeaky pedal at the same time.

[DazzaTD5]

if there is no sign of the clutch fluid going anywhere, as in if it was the master cylinder then the leak would be visible, then its as already mentioned, the slave cylinder as it leaks inside the bell housing.

Its not really a "dumb place" to put a slave cylinder. Its nothing really clever, a slave and clutch release bearing all in one, just as it was originally designed.... A Ford engine, mated to a Ford gearbox, with the same Ford clutch slave/release bearing as found in other Ford models.

It does have the advantage of giving a light clutch feel compared to Defender models of old.

It also doesnt have a clutch release fork that can break through on the pivot point.
*It also doesnt have the fiddly plastic retaining clips that hold in the slave rod.
*It also is easier to bleed the slave (a simply twist on/off at the bleed nipple)
*It is also easier to dis-connect than the earlier model.

As for the rest...
*Has a flywheel that wont fall apart.
*gearbox is easier to remove.
*Its cheaper to get the clutch replaced than the previous model (see above reasons).

If its done round that 150K then I'd be changing out the clutch assembly anyway, as in no point in doing just the slave and putting back a half worn clutch.

Regards
Daz

[Chenz]

Went home and filled the reservoir up with Dot 4 and pumped away for a few minutes on the clutch pedal.

Now have a clutch again so at least I can drive it to my mechanics to get them to do the slave. I guess it will be a do the whole clutch while you have it out seeing as it has 100K on the clock.

Wonder if this could be my Fathers Day present?

[DazzaTD5]

Wonder if this could be my Fathers Day present?

No.... its a necessary repair, look glum and depressed about the whole thing...
Also get the adapter shaft between the gearbox and transfer case checked, replaced as needed, worth looking at the pre-load on the centre diff while you are there....

A fathers day gift would be any cool accessory you need...

Regards
Daz

[Chenz]

Yeah intend to get it all checked as I I am going on a 5 week trip around Tassie. In my old 200 Tdi I had them do the clutch before a big trip and they found wear on the main gearbox shaft and a few other things which I had done while it was all apart.

I'll keep thinking of a good Dad's day gift

[Surrufus]

The hydraulic clutch release or throw out bearing is a great piece of gear in the right application.

There have been conversion kits for performance vehicles to replace clutch forks for years.

Unfortunately the internal mounting causes access issues. I have seen people cut access holes and fit screw on cover plates for access without removing the gearbox. But with a new-ish well maintained system there shouldn't be much need for regular access.