Help - Clutch Questions - 110

just pulled the slave out, with or without resistance it only pushes the piston about 22mm. That doesn't seem enough. I'm open to suggestions, but without other ideas to work on, I'll replace the master cyl again and see what happens.

Actually I'll disconnect the pipe from the master cyl to the slave, put a thumb over it and see if someone can depress the clutch, causing fluid shift within the master - not sure it'll work, but I'll let you know.

Try clamping the hose to the slave - this should give a completely solid, unmoving pedal. If it does not, it is probably the master cylinder, although check that the adjustment on the pushrod is such that the piston is fully returning.

John

UPDATE

Quote:

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Originally Posted by weeds

i had similar woes at cooma last year....we thought it may have been the pivot but it ended up being a dislodges spring in the clutch plate

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I pulled the motor out today and found the same problem, a rivet on the clutch had gone and a sping had popped. The fork looks new.

No HD Defender clutches available locally at the moment. One's due in tomorrow. I'm getting a reinforced fork with it.

While inspecting the engine I noticed a cracked flange (missing one bolt) on the fan pulley, and the bearing felt less than optimal. We used Minnithemoochas homemade flange puller to get the flange off and tomorrow I'll take the cover down to an engineering place and have them press the bearing out and fit a Ford one, and then a Ford flange (same, but machined instead of cast).

I was going to give the timing belt another 15-20K, but since the cover is off I thought I may as well do that. Then when I saw how slack the belt was, I became compelled to replace it.

Also replaced the bearing on the sprung tensioner. I know it's supposed to be a throw away item, but if you unbolt the pulley and drill a couple of little holes in the circlip, then you can remove it with circlip pliers and replace the 6202 bearing. Thanks again to Minnithemoocha for his know-how on that one.

Quote:

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Originally Posted by Michael2

UPDATE

I pulled the motor out today and found the same problem, a rivet on the clutch had gone and a sping had popped. The fork looks new.

No HD Defender clutches available locally at the moment. One's due in tomorrow. I'm getting a reinforced fork with it.

While inspecting the engine I noticed a cracked flange (missing one bolt) on the fan pulley, and the bearing felt less than optimal. We used Minnithemoochas homemade flange puller to get the flange off and tomorrow I'll take the cover down to an engineering place and have them press the bearing out and fit a Ford one, and then a Ford flange (same, but machined instead of cast).

I was going to give the timing belt another 15-20K, but since the cover is off I thought I may as well do that. Then when I saw how slack the belt was, I became compelled to replace it.

Also replaced the bearing on the sprung tensioner. I know it's supposed to be a throw away item, but if you unbolt the pulley and drill a couple of little holes in the circlip, then you can remove it with circlip pliers and replace the 6202 bearing. Thanks again to Minnithemoocha for his know-how on that one.

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That should be a 6203 bearing, Michael.:)

JC

Quote:

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Originally Posted by justinc

That should be a 6203 bearing, Michael.:)

JC

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You are right Justin and they are 6203's with the double seal. 2RS2 or similar.

This job started simple but now it will be almost a new motor when we are finished! :-)

Quote:

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Originally Posted by MinniTheMoocha

You are right Justin and they are 6203's with the double seal. 2RS2 or similar.

This job started simple but now it will be almost a new motor when we are finished! :-)

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Its a good time to do a timing belt. The clutch problem is quite common unfortunately, but good to see a few other things being tackled at once!

:):)

JC

Quote:

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Originally Posted by justinc

Its a good time to do a timing belt. The clutch problem is quite common unfortunately, but good to see a few other things being tackled at once!

:):)

JC

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We couldn't bear to do all this work and not fix it right.

Done right = Done once = More 4WD'ing Plus we love our Defer's so have to keep them in tip top shape.

Phew, the list of stuff we have now tackled is getting longer.

Hey Michael2 while we're at it lets do the tappets..........or maybe the main rear seal. On second thoughts....