Thread: Defender 300TDi clutch issue plus...

Mmmm. Installed a new Valeo H/D clutch some six months ago- no issues- drove a few thousand km until a blocked radiator stalled proceedings for a while.


Car sat for a few months waiting for me up in QLD when Harry (Ho Hars) drove it (a '96 130) onto a trailer (to have a new Turner head installed) commented that the clutch was stuffed.


When I eventually go up there and drove the car, I noticed that clutch free play at the pedal had 'gone walkabout'. The clutch bites late in the piece (top 1/3 of pedal travel).


Then, for better or for worse I drove the vehicle home to Batemans Bay.

By the time I reached the M5 bypass (Sydney)- I noticed a strange sound emanating from the trans in fifth.


Really- I've never heard a sound like someone scrunching up paper in their hands coming from any gearbox before! wt...? weird noise.


So- I stop the damned thing (0300 hrs/light rain). Let it idle and sure enough, a light knocking gravelly sound I can hear. Clutch operates ok- no shudders, nothing other than this sound that is not consistent with the revs of the motor (ie, does not vary with revs).


Ok, so put the t/c in neutral, put in gear- same thing only louder- change in cadence of the knocking/gravelly sound is noted. Not so loud in reverse, first or fourth- quite noticeable in 2nd, third and fifth.


Ended up driving the rest of the way in fourth which was great- at least I got home ok and in one piece.


BTW, the clutch pedal doesn't shudder or vibrate, no juddering at take up, synchros excellent etc etc. Pedal position (bite) hasn't changed at all- just no free play. The noise goes on depressing the clutch pedal.


I have since pulled the slave cyl to check this- nothing to report apart from the fact that it should be replaced at some point (minor leak). Slave spacer gasket - I don't know how or whether to check that this is the right thickness.


Thoughts anyone? Dead pressure plate??

Originally Posted by Svengali0

yep pressure plate diaphragm- but why would this just give up the ghost (detension) when they are nearly new... It doesn't slip in gear either- even with a bit more power coming through from the new Turner head. Fuel economy has dropped to 11/5 per hundred BTW. I guess sitting on 110 to 130km/h will do that. Runs much more smooth than before.
I'll post a video to see if anyone recognises the noise.

I doubt its the diaphragm springs, more likely the springs in the driven plate rattling.