Thread: Td5 clutch not disengaging properly after replacing clutch and flywheel

Spend the past week changing the R380 gearbox of my defender td5 due to problems with 5th gear and reverse.
Got a second hand box with 38,000km on it and replaced the clutch and flywheel with the spigot bush aswell.

After the PITA job, started the engine and guess what, could not engage any gear with the engine running. Cut off engine and all is fine.
Eventually I bled the hydraulics 4 times to be sure there was no air in the master and slave cilinders, but did not help.
When starting the engine with the car in gear and clutch depressed. All seemed fine and i could take off as always, no problems, untill I want to change gear.
The biting point of the clutch was very low, I need to release the pedal a tiny bit and the car takes off.

Then I adjusted the master cilinder rod where it is attached to the pedal untill there are only 2 to 3 threads sticking out of the nut at the end of the rod. The 17mm nut that limits pedal travel downwards is also adjusted so that the pedal hits the floor.

Biting point is way higher now and I CAN get it into gear now, but it still takes some force to do so. When driving, all is fine and shifts go pretty smooth, but still not as smooth as it should be.
When standing still again it takes more effort to select gear, and reverse is still very difficult to select!

I am pretty sure I installed the disc the right way, with gearbox side facing gearbox side, altough when having this sort of problems offcourse i start to doubt if I did installed it correctly as I always had a memory full of holes

Replaced the spigot bush aswell and when mounting the box back to the engine the last quarter inch we were unable to close the gap and I did use the bolts to pull the box against the engine. It was the only way altough I know I should not do it this way. I thought the input shaft could be sticking in the spigot bush , but after driving 2 days I guess it should be loosend up right ?

To me it seems like the input shaft still does not release properly of the engine and keeps turning a little bit when clutch depressed.

Does this sound familiar to anyone on here as I ran out of ideas what the problem could be ...

Niels

Mate (a very competent Landy man) once said to me (when replacing Rangie clutch) if you drop the engine you'll probably need a new sump, drop the gearbox - well totally different story.


Martyn