Disco 2 Oh dear, not good news i fear

dimbers · Jan 20, 2019

On my way to get some beers from the local sainsburys, pushed the clutch in and heard something break, the clutch has no resistance now and fluid everywhere underneath.

The clutch had been slipping now and again in high gears so knew it needed doing, but what has failed now? Im guessing slave or master cylinder? I also notice that the brake warning light it now staying on.

Its an 04 td5 manual. Like i say its been slipping sometimes anyway, but i also have a crunch into first and second gears as well as the bias plate needs replacing.

I need to work out what my cheapest option is. Replace clutch, dmf, bias pate and have the gearbox reconditioned!! As well as have whatever broke tonight fixed, I think thats gonna cost a small fortune which i just wont be able ro do right now. Is there any other options i can look at? Anyone have a rough idea of what the above is likely to cost?

Thanks in advance

Kev12 · Jan 20, 2019

If you heard something break its unlikely to be hydraulic, so fork, roll pins, pressure plate or release bearings are likely candidates.
Cost depends on if you are doing the work or paying someone

dimbers · Jan 20, 2019

Thanks for reply, i went and had a look with a torch, it seems that the slave cylinder has come off. Ive ordered a new one and some brake fluid as i believe they share the same reservoir? One thing i need to find is where i can get some new bolts, the old ones must have been what i heard clattering the underside as they fell off.

Landmark2 · Jan 21, 2019

Yes they do share the same resevoir which is why your brake warning light has come on. First time I've heard of a salve cylinder coming off. Lets hope there is nothing gone wrong inside the bell housing to have caused it.
Griff

dimbers · Jan 26, 2019

I went to fit the new slave cylinder, but found that the bottom bold had snapped, which i managed to remove. Worse though i found that the top bolt will not tighten, it seems the threads inside the mount have stripped off.

Looks like my best bet is new box, clutch and flywheel. Any recommendations on where to get a good unit from?

DanClarke · Jan 26, 2019

Can the failed threaded hole not be fixed with a helicoil?

dimbers · Jan 26, 2019

DanClarke said:
Can the failed threaded hole not be fixed with a helicoil?

Probably, but then im sure there will be some other reason that caused it ro happen in the first place. I think by the time i have the gearbox removed, 1st and second syncro done and any other work that needs doing it would be quicker and possibly cheaper to replace with a reconditioned unit. Just been looking at ashcroft and it doesnt seem a bad deal

Alpinejim · Jan 26, 2019

If you really need work done on your box then I’d say an Ashcroft box is not a bad buy.
I recently reconditioned my box - no point just doing 1st/2nd synchro, you could do with new bearings and baulk rings too, plus whatever else you find is wrong, plus labour if you don’t do it yourself. Much more than a recon from Ashcroft.
I spent nearly as much as a recon would have cost but I gained some knowledge on how it works at least. I got Ashcroft to do the HD upgrade to the rear housing too.

If you think you need 1st/2nd synchro because of poor gear changes, it could have been caused by the slave. Every time you clutch, the slave moves out rather than operate the clutch. I reckon you should replace slave and Helicoil the hole then see if your gear change improves.
Could be tight to Helicoil depending which one stripped but worth a go I think.

Alpinejim · Jan 26, 2019

The bolts you need are fairly common. I think they are M8x1.25, probably 25mm long.
Look up at Brit Car or local dealer.

Disco 2 Oh dear, not good news i fear

dimbers

Active Member

Kev12

Well-Known Member

dimbers

Active Member

Landmark2

Well-Known Member

dimbers

Active Member

DanClarke

Well-Known Member

dimbers

Active Member

Alpinejim

Active Member

Alpinejim

Active Member

Similar threads