Unable to engage gear after replacing Master&Slave

gmacalex · Aug 18, 2015

Hello,

I purchased my freelander 1 1.8es 2003 about 3 weeks ago, at the time I was aware that the clutch was very heavy but usable,however big chief was not impressed as she could not change gear. I looked at the many useful post on here and decided to look at the clutch hydraulics, and sure enough the slave was mangled, so I ordered the new part and fitted it today, I know people fit it within 30 mins, but not me took me 20mins to just to get the master attached to the clutch, but I stuck to the the task and was happy it was fitted.
But now I cannot engage any gear unless I press the clutch through the floor and jam the stick into reverse, so now I am out of pocket, no car and I can't see an alternative solution, I looked at the clutch release arm I don't know how free to move it should be I can move it but need to use heavy bar screwdriver, I sprayed wd40 and some 3 in 1 oil but it has not made much difference, the slave moves about an inch.

I was careful not to let any air in sealed unit and there does not appear to be any leaks, and ideas or advice would be greatly appreciated, I am on a very tight budget and a beginner DIY mechanic.

Many Thanks
Gordon20150817_160101.jpg

gstuart · Aug 18, 2015

gmacalex said:
Hello,

I purchased my freelander 1 1.8es 2003 about 3 weeks ago, at the time I was aware that the clutch was very heavy but usable,however big chief was not impressed as she could not change gear. I looked at the many useful post on here and decided to look at the clutch hydraulics, and sure enough the slave was mangled, so I ordered the new part and fitted it today, I know people fit it within 30 mins, but not me took me 20mins to just to get the master attached to the clutch, but I stuck to the the task and was happy it was fitted.
But now I cannot engage any gear unless I press the clutch through the floor and jam the stick into reverse, so now I am out of pocket, no car and I can't see an alternative solution, I looked at the clutch release arm I don't know how free to move it should be I can move it but need to use heavy bar screwdriver, I sprayed wd40 and some 3 in 1 oil but it has not made much difference, the slave moves about an inch.

I was careful not to let any air in sealed unit and there does not appear to be any leaks, and ideas or advice would be greatly appreciated, I am on a very tight budget and a beginner DIY mechanic.

Many Thanks
Gordon20150817_160101.jpg

hi mate , I've got an auto so my knowledge is abit limited

not being rude have u tried bleeding it out with all new clutch fluid to see if it helps at all , to eliminate any possible air and renewing any old fluid due to deteriation

assume the clutches pressure plate and release arm are all ok

sorry can't help u a lot more than that I'm afraid

gmacalex · Aug 18, 2015

Thank you for taking the time to reply, according to this site the master slave is a sealed unit and can't be bled, so I am kind of stuffed, I am going to try and free up the clutch release arm if possible.

gstuart · Aug 18, 2015

gmacalex said:
Thank you for taking the time to reply, according to this site the master slave is a sealed unit and can't be bled, so I am kind of stuffed, I am going to try and free up the clutch release arm if possible.

ok mate , no probs,

one of the other guys should be able to shed more light on it then

just assumed there would be a bleed point , will have to read up on it now, got me thinking , lol

gstuart · Aug 18, 2015

is this any good, look at number 1 at the top about a bleed point on the slave

gstuart · Aug 18, 2015

here's the other page , says about a pushrods correctly engaged ??

hopefully u can zoom in

plus have u downloaded the rave manual , is very good and free

gstuart · Aug 18, 2015

hope it may help a little bit in order u can resolve the problem

gmacalex · Aug 18, 2015

Thank you, I will download the rave manual, as I reckon I will need as much help as possible.

gmacalex · Aug 18, 2015

Hello,
I have tried to free up clutch release and although better not great, in the meantime I thought I could check the oil in gearbox, but have no idea if there is a dipstick or where even to look, any help would be appreciated.
cheers

xpuser8334 · Aug 18, 2015

Hi. I'm having the same issues with a TD4, but.... I've just had to pull the engine and box to get to my slave cylinder.
Anyway....

xpuser8334 · Aug 18, 2015

Depends on which box you have.. it's usually a case of undoing the filler bung - i have the same type of oil in a proper canister, and I pump a little in to the filler bung until it runs out. I wait for the running to stop and fit the bung again....
although - I may be doing this wrong....
if you can see which box is yours from the images.. let me know and I will upload the destructions for you as an image

xpuser8334 · Aug 18, 2015

gmacalex · Aug 18, 2015

xpuser8334 said:
Depends on which box you have.. it's usually a case of undoing the filler bung - i have the same type of oil in a proper canister, and I pump a little in to the filler bung until it runs out. I wait for the running to stop and fit the bung again....
although - I may be doing this wrong....
if you can see which box is yours from the images.. let me know and I will upload the destructions for you as an image

Thank you I think its the PG1 gearbox the freelander is a 2003 1.8 es but not facelift model. Really hoping this will help. Thanks

xpuser8334 · Aug 18, 2015

If you are checking the levels; don't take out the DRAIN plugs.... (unless you are replacing the oil)

gmacalex · Aug 18, 2015

Thanks was on my way back downstairs to start undoing bolts...good save.

xpuser8334 · Aug 18, 2015

Alibro · Aug 18, 2015

gmacalex said:
Hello,
I have tried to free up clutch release and although better not great, in the meantime I thought I could check the oil in gearbox, but have no idea if there is a dipstick or where even to look, any help would be appreciated.
cheers

If you don't know the history of the car it is a good idea to change the gearbox oil. Chances are it has never been done, here is a link to a video showing how it's done.

You can get transmission oil from any good motor-factor.
Regarding the shaft, it can get a bit rusty so lots of release oil over several days should free it up.

gmacalex · Aug 18, 2015

Brilliant thank you I will try this tomorrow, no joy freeing up the release so maybe new oil will do the trick.

gmacalex · Aug 18, 2015

Before I do this do I have to use a torque wrench as I don't own one, I take it the trick is to not over tighten?

Thanks

Alibro · Aug 18, 2015

gmacalex said:
Brilliant thank you I will try this tomorrow, no joy freeing up the release so maybe new oil will do the trick.

I don't think new oil will make any difference to a sticky shaft as it doesn't go near the oil. You need to spray it several times over a few days to free it up.

gmacalex said:
Before I do this do I have to use a torque wrench as I don't own one, I take it the trick is to not over tighten?

Thanks

Ermm, I didn't use a torque wrench while doing mine but I have been working at cars for 30+ years so kinda know by feel how much to tighten.
You could do worse than this onefrom Amazon. As you bought a 1.8 you'll probably need it some day for the head gasket.

Draper 28757 3/8-inch 10 - 80mm Square Drive Ratchet Torque Wrench
Just remember you will also need an adapter to use it with a 1/2" socket set although a lot of sets have one included. It is the funny looking thing you can poke an extension rod through.

Unable to engage gear after replacing Master&Slave

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