Thread: 300Tdi Overhaul manual, and clutch slave tool

I found this on the web;

http://www.roversclub.org/docs/300TD...aul_Manual.pdf

This from "acer3505"


Clutch slave cyl pushrod clip insertion tool My first post ... hope this helps someone.
I recently replaced the clutch slave cylinder on my 300 tDi 130 Defender. Of course the pushrod retaining clip came loose in the process.

After a bit internet searching I got the general idea how it might be replaced.

I used a piece of 10mm dowel and center drilled it so the pushrod was a sliding fit - PVC or stiff plastic tubing would also work I'm sure. At one end I slit the dowel at 4 sites 90º apart.

A couple of daubs of Correct-it fluid on the back of the clip made alignment easier to spot inside the housing. My wife wound and tied off 3 wraps of cotton around the prongs when I slightly compressed them, then a piece of fishing line was tied around one one of the three wraps.

Insert rod into clip then into dowel. At the slit end wrap a small cable tie around and tighten such that the cable tie lock is opposite the clip prongs and the rod /clip is locked to the dowel.

Insert device into slave cyl hole align via cable tie, hold your tongue correctly , swear a bit and then press it home. Once you are sure (I checked with a small mirror), yank the fishing line whilst pressing against the rod end , off comes the cotton and hopefully the clip stays there. Nip off cable tie and slide off dowel.The attached photo shows the general idea .