Seeking advice regarding defender slave cylinder push rod/ clutch fork retaining clip

Shanec · Jan 1, 2016

In a bit of a foolish situation

Pulls out the slave cylinder rod from the bellhousing with long nose pliers and the clutch fork retaining clip came with it.

First time doing a slave cylinder replacememt .

Suspecting I've put myself in a gearbox off situation?

I just can't work out how to get the retaining clip back in the hole, and even tricker, get of sitting correctly.

I think if I try the rod will fall into the bellhousing and I'll need to drop the box off.

Or can I throw retaining clip in bin and hope the rod doesn't slide side to side?

Dragonwalker · Jan 1, 2016

Shanec said:
In a bit of a foolish situation

Pulls out the rod from the bellhousing with long nose pliers and the retaining clip came with it.

First time doing a slave cylinder replacememt .

Suspecting I've put myself in a gearbox off situation?

I just can't work out how to get the retaining clip back in the hole, and even tricker, get of sitting correctly.

I think if I try the rod will fall into the bellhousing and I'll need to drop the box off.

Or can I throw retaining clip in bin and hope the rod doesn't slide side to side?

Is this on your D2 ?

Shanec · Jan 1, 2016

Hi sorry this is on my defender 110 200 tdi

Dragonwalker · Jan 1, 2016

It's a git of a job
http://forums.lr4x4.com/index.php?showtopic=89405
but it has been known to use a tank cutter to cut a 20mm hole to assist the job and put a EGR blank over the hole
Worst way is box off

jamesmartin · Jan 1, 2016

if you hold rod in its seat whilst you fit slave once pushed up it should stay in place without the plastic clip, ive done it a few times for people as its natural just to pull of slave which can often pull rod off,unless your aware

blue beasty · Jan 1, 2016

jamesmartin said:
if you hold rod in its seat whilst you fit slave once pushed up it should stay in place without the plastic clip, ive done it a few times for people as its natural just to pull of slave which can often pull rod off,unless your aware

I agree. Have done 1000s of miles without problems with no clip.

A blob of grease on the end of the rod can be helpful to hold the rod in place as slave is offered up.

Shanec · Jan 1, 2016

Thanks for the link. As its getting towards sunset I'm going to just try with hosepipe and luck. If I have to put together without it and it goes whilst driving I've not lost anything. Drove it 80 miles today without clutch pedal anyway!

Shanec · Jan 1, 2016

JM and BB thanks for confirming. Here we go what will be will be.

Marmaduke · Jan 1, 2016

When my brother did this with his defender I ended up melting the tip of a screwdriver into the plastic part so I'd got some control and a way of pushing it back into the clutch fork. It took a fair few goes but got it in there eventually

Shanec · Jan 1, 2016

Some chuckle material for those who know what they are doing. poo hit fan. Rod has fallen into bellhousing. Will get a flexible rod magnet tomorrow.

Marmaduke · Jan 1, 2016

D'oh

Don't know where I had it from but I've got a small magnetic LED torch on the end of a flexible shaft

Shanec · Jan 1, 2016

Just hoping do not need to take box out. Engine cradle OK, time to take everything apart not OK. And I round heads.

Marmaduke · Jan 1, 2016

If all else fails try to hook it with an old fashioned metal coat hanger

Shanec · Jan 1, 2016

How's that going to work, put coat hanger into a small loop at end and go fishing?

Marmaduke · Jan 1, 2016

Leave the hook on the end and try to drag it back to the slave cylinder hole

Shanec · Jan 1, 2016

Will try thanks

Shanec · Jan 2, 2016

Bought from machine mart both flexible claw pick up tool and pickup tool magnetic, which has a light on the end too.

Shanec · Jan 2, 2016

Got it in the end. Had fallen south toward middle of vehicle. Magnetic head wasn't flexible so bent it 90 degrees got it that way. I can see why holes are cut...

Next issue is I've got two new slave cylinders and both have different length push rods. One has a bleed screw flat facing to the slave body, the other is at an angle.

No idea which one to use.

Also no idea if rod has pushed through fork! Oh dear...

jamesmartin · Jan 2, 2016

there is only 1 size of rod fitted as std

Shanec · Jan 2, 2016

I didn't know what gearbox I had so I got both sizes. I now know I've got lt77 because reverse is to the left of first. However, the rods I bought are land rover genuine, they are both longer than what came out of the vehicle.

Pushed a screw driver in and found the fork not to be punched through thankfully.

Seeking advice regarding defender slave cylinder push rod/ clutch fork retaining clip

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Leaks an prone to bits dropping off

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