Cannot select gears, tried a bunch of stuff but can't figure this out !

Danny champion · Jul 19, 2020

Hi all, wonder if anybody could help me with this as it's driving me mad!!

I recently developed a problem with my my 300tdi defender 90,(205k) I couldn't select any gears at all, then the problem mysteriously went away, and then came back and the only way I could get it into gear was to put the transfer box into neutral, select a gear and then put the transfer box back into either high or low and that way I could move the vehicle, although I could not change gear.

I have taken the shift turrett off and checked that everything is connected as it should be, I was then advised that this pointed to an internal issue so I have changed the gearbox for another of unknown condition, although the vehicle it came from (Discovery) had only 110k miles on it. I had an engine change 10000 miles ago and on inspection the clutch looked fine so I did not change it at that point.( Wishing I had now though even just to rule it out!!) before fitting me and a friend (who is experienced with land rovers) checked the gearbox over ,and everything seemed fine, no excessive play, went into every gear etc.

It was fine for about 3 miles then the problem returned I bled the clutch system and again it was fine for about 5 minutes and then the problem recurred. I have since changed both master cylinder and slave cylinder and again all was fine 5 minutes and then the problem return again.

I have been searching forums and can find and no answers I am really p!##£d. Off with the thing now,and desperately need to get it back on the road. I would really appreciate any thoughts or advice before I go ahead and change the clutch (possibly unnecessarily).

Many thanks from a newbie!

jamesmartin · Jul 19, 2020

sounds like clutch isnt clearing, could be a worn cover plate requiring too much travel too clear, or could be your not getting enough travel which could be various things like cylinders ,rod ,lever etc hows pedal feel

Danny champion · Jul 19, 2020

Wow thanks for the quick response! The pedal feels perhaps a touch light, difficult to say. Forgive my ignorance the cover plate is the metal plate which sits over the friction plate?

Danny champion · Jul 19, 2020

Just googled it. I think that was replaced along with everything else about 10000 miles ago could I really have one through a clutch in 10000 miles? I do do a reasonable amount of towing but surely that seems excessive...?

Danny champion · Jul 19, 2020

When I put in the new master cylinder I made sure the adjustment was exactly the same as the old one. when that didn't work I adjusted it almost to the end of the thread for a bit more leverage and it didn't seem to make any difference...

Moron · Jul 19, 2020

Try selecting all gears with the engine NOT running ......if all gears can be selected with normal effort , try again with engine running ......if the problem is there with engine running its a clutch problem ......probably hydraulics hths

Danny champion · Jul 19, 2020

That's exactly what happens,e running nothing. engine off all gears no problem. I have replaced both slave and master cylinder and bled the system so I'm guessing it must be the clutch then...?

Moron · Jul 19, 2020

Danny champion said:
That's exactly what happens,e running nothing. engine off all gears no problem. I have replaced both slave and master cylinder and bled the system so I'm guessing it must be the clutch then...?

If you're sure its been bled correctly ......ie no air left in the system
The fact you bled it and it was fine for a short time points to hydraulics

Danny champion · Jul 19, 2020

I'll give it another go tomorrow just to be sure..

Thanks for the advice I'll let you know how I get on.

Kev12 · Jul 19, 2020

Unlikely to be the clutch plate after 10k but could be something else inside, either the arm is failing (although they usually fail completely and suddenly) or release bearing is u/s. I have known a cheap release bearing last less than a week with an unsympathetic driver

Rougharse Racing · Jul 20, 2020

My money is on the clutch, the arm can wear through as others have said, but the pads that attach the arm to the release bearing can also wear out.
I think you need to bite the bullet and take the gearbox out and check the clutch.

freelance · Jul 20, 2020

Change the flex hose, it could be ballooning

Danny champion · Jul 21, 2020

Many thanks for the ideas guys, I have a friend coming over tomorrow and we'll get into it then, so hopefully I'll have news after that,a with a bit of luck a working
land rover!!

Hicap phill · Jul 21, 2020

As you have changed the slave cylinder....
You have put it back the correct way??
(Nipple at the top)

Rebz · Jul 21, 2020

Interested to see how this develops. Have a similar issue with a 96 110 300tdi 206k, truck was off the road during lock down mechanically was fine when i parked it up (lets not talk about electrics) started her and clutch wouldn't disengage, can drive her clutchless no drama so friction plate is ok, checked fluid and pressure at slave bleed (suggesting master is good), though mine happened far more suddenly. My money is on the clutch arm for both of us ...and that sucks :/. I will change the slave anyway in vain hope

Danny champion · Jul 22, 2020

Rebz said:
Interested to see how this develops. Have a similar issue with a 96 110 300tdi 206k, truck was off the road during lock down mechanically was fine when i parked it up (lets not talk about electrics) started her and clutch wouldn't disengage, can drive her clutchless no drama so friction plate is ok, checked fluid and pressure at slave bleed (suggesting master is good), though mine happened far more suddenly. My money is on the clutch arm for both of us ...and that sucks :/. I will change the slave anyway in vain hope

Danny champion · Jul 22, 2020

We checked the condition of the arm and release bearing when we had the engine and gearbox apart, all seem fine…

Rougharse Racing · Jul 22, 2020

Rebz said:
Interested to see how this develops. Have a similar issue with a 96 110 300tdi 206k, truck was off the road during lock down mechanically was fine when i parked it up (lets not talk about electrics) started her and clutch wouldn't disengage, can drive her clutchless no drama so friction plate is ok, checked fluid and pressure at slave bleed (suggesting master is good), though mine happened far more suddenly. My money is on the clutch arm for both of us ...and that sucks :/. I will change the slave anyway in vain hope

Sounds like your clutch plate may have stuck if it has been standing for a while, try starting it up in 1st gear with the clutch depressed and then apply the foot brake hard.

Kev12 · Jul 22, 2020

If you are certain you have fitted and bled the hydraulics correctly, that only leaves mechanical parts so either something in the bellhousing or the gearbox itself

Flossie · Jul 22, 2020

Rougharse Racing said:
Sounds like your clutch plate may have stuck if it has been standing for a while, try starting it up in 1st gear with the clutch depressed and then apply the foot brake hard.

+1. ^^^^^
Friction plate rusts to the flywheel, very common on standing vehicles.

Cannot select gears, tried a bunch of stuff but can't figure this out !

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