Disco 2 Clutch pedal travel is not right.

neilly · Mar 16, 2018

So,

After travelling to sunny ( read WET) Cornwall last Friday , on the way back I realised when changing gear that the clutch pedal feel had changed.

It would appear the top half of the pedal travel is now slack ( no resistance at all ) then the bottom half has a normal feel to it. Clutch does work , gears engage but they are not as smooth as they were. Drives as it should in gear.

Fluid level has not dropped, does not feel like it has air in it.

Guess it is time to have the clutch out and have a look.

Something is not as it should be in the realm of clutchville.

Cheers

Shimsteriom · Mar 16, 2018

My clutch has always been like that, even after a new DMF and clutch plate, so I'll be watching this fred...

neilly · Mar 17, 2018

This clutch is only 25K old including a new flywheel, done by the PO.

So , next question what size tool is needed for the clutch alignment?

Cheers

neilly · Mar 17, 2018

neilly said:
This clutch is only 25K old including a new flywheel, done by the PO.

So , next question what size tool is needed for the clutch alignment?

Cheers

Found the sizes, now to find a tool to do the job.

Cheers

brian47 · Mar 17, 2018

It could be something as simple as a broken or missing return spring (if there should be one) on the clutch release bearing fork.

neilly · Mar 17, 2018

brian47 said:
It could be something as simple as a broken or missing return spring (if there should be one) on the clutch release bearing fork.

Not sure quite what you mean there Brian? drawing of what is in there.

Cheers

Magicgrotto · Mar 17, 2018

Just LOOK in a Mirror @neilly

neilly · Mar 17, 2018

Magicgrotto said:
Just LOOK in a Mirror @neilly

I just knew that would get a response....LOL...........

Cheers

Magicgrotto · Mar 17, 2018

that much of a response you had to look twice !!

brian47 · Mar 17, 2018

neilly said:
Not sure quite what you mean there Brian? drawing of what is in there.

View attachment 144682

Cheers

Sorry, but I wrote it before I checked in RAVE. In the olden days, the clutch release was assisted by a small spring to actually pull the release bearing away from the actuating fingers and close the slave cylinder to it's normal position if that makes sense.
I can see now that my reasoning is spurious since no such spring is fitted.
But it was worth a thought.

neilly · Mar 17, 2018

brian47 said:
But it was worth a thought.

True, is strange how it feels.

Basically clutch is now actuating over half the stroke at the bottom end and does not feel quite 100% when changing gear.

Cheers

brian47 · Mar 17, 2018

neilly said:
True, is strange how it feels.

Basically clutch is now actuating over half the stroke at the bottom end and does not feel quite 100% when changing gear.

Cheers

It's not something like the fork arm getting cracked and/or bent, is it? There have been some reports of that sort of thing happening. That could give rise to those symptoms too. Either way, you're going to have to get into the bit between the lump and the box.

neilly · Mar 17, 2018

brian47 said:
It's not something like the fork arm getting cracked and/or bent, is it? There have been some reports of that sort of thing happening. That could give rise to those symptoms too. Either way, you're going to have to get into the bit between the lump and the box.

Yep, already planning that, just enjoying the fact the temp has plummeted this week....

, Going to pull the engine forward next week hopefully..

I thought the fork issue was fixed on the td5's following the issues on the 300tdi's.

Cheers

brian47 · Mar 17, 2018

neilly said:
Yep, already planning that, just enjoying the fact the temp has plummeted this week...., Going to pull the engine forward next week hopefully..

I thought the fork issue was fixed on the td5's following the issues on the 300tdi's.

Cheers

Well, best of luck. Keep us posted when your fingers thaw out.

Magicgrotto · Mar 17, 2018

If this keeps up you wont get it done before June 1/4" in 20 mins

total white out

Kev12 · Mar 17, 2018

Could be a hydraulic problem, any signs of a leak from master & slave? Does pumping improve it?

Shimsteriom · Mar 17, 2018

If Neillys clutch pedal issue is the same as mine, then I had a new master and slave installed with the new clutch, and there's no leakage, yet I still have the same issue. So maybe not a cylinder problem?

I've just learnt to live with it as I've never known any better and it doesn't seem to cause any problems

dieseldog69 · Mar 17, 2018

neilly said:
Yep, already planning that, just enjoying the fact the temp has plummeted this week...., Going to pull the engine forward next week hopefully..

I thought the fork issue was fixed on the td5's following the issues on the 300tdi's.

Cheers

Td5 has cast steel fork arm as opposed to the pressed steel one of 300Tdi

Just a thought, what release bearing did PO fit? Plastic one or alloy HD one?

Perhaps the long motorway journey heated it up and the plastic has melted?

kevstar · Mar 17, 2018

My clutch is the same on my D2 & I also have a noise the off release bearing every now & then but only
when I engage first gear & the clutch is to the floor. I will wait until it breaks before I do anything about it.

"Its no broke yet so I'm no fixin it"

Goc3k · Mar 18, 2018

Not sure if it is relevant, but I bought my D1 with a similar problem - turned out to be the part I've circled in the diagram - it was press fit into the guide / arm (annotated no. 1) and had almost fallen out, not sure if it is the same on the D2's but will be worth checking when you take it apart

Disco 2 Clutch pedal travel is not right.

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