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Thread: 200tdi / R380 Clutch dramas

  1. 21st June 2010, 07:38 PM #1
    bushy555
    bushy555 is offline Fossicker
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    200tdi / R380 Clutch dramas

    Hi All,

    Did a bit of a seach thinking I might accidently come across the answer to my current clutch drama.

    200tdi mated to a R380. Been like it for 12 years.
    The 200tdi came out and in went a 200tdi that was previously mated to a LT77 gearbox. I did not change anything on the clutch/flywheel of the LT77 200tdi engine, thinking that it should just slot straight in. Everything appeared to measure up fine. (...had to change a stud, drill one hole and change four bolts for the R380 bellhousing to fit on the LT77 200tdi).

    Anyway, all good, up until trying to put it into gear when engine running. It appears as though the throw-out/spigot bearing arm isn't throwing far enough to disengage the clutch. With the above configuration, should it still work?

    I made up a slave cylinder push rod extension of 15mm, which helped a little but not enough. There is bugger all free play in the clutch pedal. It feels as good as it has ever been, with a very strong feeling of it engaging/disengaging correctly.
    Will it work if I was to make up an extension of 30 or 40mm? Will an extension in the master cylinder also help the slave in its travel?

    ...or do I need to pull the LT77 200tdi engine out, and swap over clutch/flywheels?

    Any pointers would be greatly appreciated.

    dave
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  2. 21st June 2010, 10:16 PM #2
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    rick130
    rick130 is offline Moderator Gold Subscriber
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    I know it sounds basic, but are you getting full travel from the slave cylinder piston ?

    Does it need a re-bleed ?

    Has the m/c gone to God ?

    Wouldn't be the first time a 'coincidence' like this has happened.
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  3. 22nd June 2010, 04:28 PM #3
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    LowRanger
    LowRanger is offline ChatterBox Subscriber
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    If I read it correctly,you fitted a different motor (200Tdi) and used the flywheel and clutch assembly off this new motor with your original gearbox.
    If this is correct 1id you compare the height of the flywheel?
    2id you compare the height of the pressure plate?
    If both of these measurements were checked and ok,then are you getting full stroke of the slave?As stated,it isn't unusual for hydraulics to fail when the perssure is released off them and suddenly the seals are allowed to travel over an area inside the cylinder,that is not normally used,and may contain some form of contamination that will damage the knife edge seal ?

    Wayne
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  4. 23rd June 2010, 02:04 AM #4
    Ian Ashcroft
    Ian Ashcroft is offline Fossicker
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    Wink 200Tdi/R380 Clutch drama

    Hi just a thought, could your spigot bush be tight on the pinion shaft!, it will have a very similar effect to draging clutch??. Regards Ian Ashcroft
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