What have I missed out? Clutch won't work

JackSeriesIII · Dec 23, 2012

I have just come to drive my series 3 200tdi out if the garage and the clutch won't work it's fully bled and has a new master and slave cylinder. On further inspection the clutch release bearing doesn't reach the pressure plate to release until the pedal is right at the bottom of its swing.

I have searched and have a mixed bag of results 1, is to extend the shaft to push the clutch fork further another is to weld a spacer to the pressure plate but this would cause balancing issues surely, I'm stumped and am after a quick answer if anyone has experienced this before ? Ill upload some pictures in a minute.

Cheers

JackSeriesIII · Dec 23, 2012

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That is with the release shaft in the correct position for a standard series pressure plate which was working before the new engine it is a discovery clutch cover.

2D64F61F-AC96-44A0-9B8C-82F3037E6117-152-0000000624EBF329.jpg

And this is where the pedal is about 30 mm away from the floor plate and jut doesn't give enough travel to operate the clutch.

foxyjam · Dec 23, 2012

Hole in the clutch arm allowing the push rod to go through?

jamesmartin · Dec 23, 2012

plus plastic cup that sits over pivot in the release arm ,what slave cylinder did you use series 3 ?if you havent missed anything out you can use a longer push rod to get you going

Rattlegun · Dec 23, 2012

If its a tdi conversion, I thought it should be using the series cover?

Pikey · Dec 23, 2012

foxyjam said:
Hole in the clutch arm allowing the push rod to go through?

think not. it's a tdi engine in a series with a series gearbox.

It looks to me like the clutch plate is flat as a pancake.(though that could be the photo angle) how old is it???

JackSeriesIII · Dec 23, 2012

I don't believe there is a hole in the clutch arm we have only just built it and there wasn't one there when we put the new clutch in. The cover is brand new, off a discovery 200tdi it's britpart which may be my problem? Should the arms stick out at an angle I believe they should but can't remember what the series engine cover looked like, it was a while ago when I took it off. The arms on the clutch cover are flat, just building a longer shaft to try, if not though will have to split the engine and gearbox.

Does anybody have a picture of their clutch cover on the 200tdi?

Turboman · Dec 23, 2012

JackSeriesIII said:
I don't believe there is a hole in the clutch arm we have only just built it and there wasn't one there when we put the new clutch in. The cover is brand new, off a discovery 200tdi it's britpart which may be my problem? Should the arms stick out at an angle I believe they should but can't remember what the series engine cover looked like, it was a while ago when I took it off. The arms on the clutch cover are flat, just building a longer shaft to try, if not though will have to split the engine and gearbox.

Does anybody have a picture of their clutch cover on the 200tdi?

The spring fingers in the middle of a new clutch usually stick up slightly forming a dome around the centre hole. Like redhand said those fingers look completely flat, maybe its the photo?

JackSeriesIII · Dec 23, 2012

Ok, i looked back at the pictures of the 200tdi when i picked it up and the clutch plate forks did stick out considerably more than the ones on the engine at the moment, my guess is that this is my problem. I have fitted an extension piece to the fork shaft but this just made the fork hit the back of the gearbox thus not allowing the movement required to release the clutch.

Has anybody else experienced this with a brand new Britpart clutch cover?

jamesmartin · Dec 23, 2012

i have as with genuine too were the fingers werent sprung but just bent,but have you got friction disc the right way round

JackSeriesIII · Dec 23, 2012

There is a right way round? The plate looked to be equal I.e can be put on either way round.

jamesmartin · Dec 23, 2012

the friction material is the same but center isnt

Pikey · Dec 23, 2012

JackSeriesIII said:
There is a right way round? The plate looked to be equal I.e can be put on either way round.

only fits one way. Usually has "fit this side to flywheel" stamped on it..

JackSeriesIII · Dec 23, 2012

Ok I must have fitted it the correct way round don't think I would have got it wrong as it would hit the flywheel. Ill pull the gearbox off tomorrow and check that as the likely hood is the clutch cover needs changing or something else is at fault.

jamesmartin · Dec 23, 2012

JackSeriesIII said:
Ok I must have fitted it the correct way round don't think I would have got it wrong as it would hit the flywheel. Ill pull the gearbox off tomorrow and check that as the likely hood is the clutch cover needs changing or something else is at fault.

i sure you have fitted it correctly its fairly obvious but it has been done,its more common now to find poor clutch covers ive had a few ive had to do twice

pissant · Dec 24, 2012

think we should all learn to "avoid the blue box"

aaronledwidge · Dec 27, 2012

Im pretty sure i used the series 3 complete clutch asebmly on mine and not the discovery cover, maybe thats where your issue lies?
I didnt think the discovery cover would work with the series box, or are you using a disco box?

JackSeriesIII · Dec 28, 2012

Problem solved. I went to John Craddocks and got a genuine Landrover 200Tdi clutch cover and this didnt pull up any different to the britpart one but left the new one on for obvious reasons.

In the end we modified the clutch fork to push the bearing 12mm closer to the pressure plate works a treat now. I still havent got a clue as to why there was a problem in the first place as that many people have done the conversion now and never seem to have had this problem. My thinking was that the gearbox may be a series 2A ? as that had a spacer boss on the clutch pressure plate, only a thought.

Have had it out the garage and it drives fine no issues with the clutch power steering is lighter than my skodas

should be good for the 265/75/16 tyres when i get some. Now got a problem with the wipers going in opposite directions so guess that is a dashboard off job.

Anyway thanks for the help trying to solve the problem guys.

foxyjam · Jan 9, 2013

Glad you're now mobile

The series 2 gear box's didn't have synchro on first and second gears and have to double clutch going into these two gears. Series 3 boxes have synchro on all gears so should be easy to tell.

The wipers on series should both point into centre of screen when parked, unless someone previous has changed them. I'll put pictures up both inside and out. The wiper drive worm gear thing should go over the wiper drive inside cab on left one and over the right side, but by now you've possibly got that sorted.

foxyjam · Jan 9, 2013

Picture of my bro's series three outside and my series 2 inside as no dash and can see the mechanism

What have I missed out? Clutch won't work

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