Hi guys, I just want to pick your brains before pulling the engine out if I can. in June last year I fitted a Valeo Heavy duty clutch kit to the Disco, apart from a few problems refitting the gearbox, all went went well and the Disco was back up and running. However after about 11000 miles I noticed that occasionally when accelerating in 3rd, the revs would rise with no increase in road speed, forcing me to ease off the peddle, the revs would then die back down and I could accelerate almost normally. I also noticed that the amount of pressure required to release the clutch was extremely small. The peddle has a small amount of free play but you only have to touch the peddle beyond this to effect the clutch. I have also noticed that when driving up hill in 3rd, just before the point where you need to change down, I get the same clutch slippage. I say 3rd because it seems more noticeable in this gear, which is probably due to the torque.

I have spoken to Mail Order 4x4 and they are happy to sort me out under warranty even though the 12 months has expired, but as they said, they have never had a problem with a valeo clutch in the past.

Oil contamination is one possibility but the oil level seems to remain constant and I have never seen any oil leakage or drips anywhere underneath. Also the wading plugs are out. Some one mentioned the rear crank oil seal might have gone but I would expect this to drip down the back of the fly wheel and also any oil build up over night would make the problem worse in the mornings, which isn't the case. I've now covered 14500 miles and the problem hasn't got any worse.

Has anyone encountered anything similar in the past or is there anything I can check before I commit to pulling the lump out and having a look?

it sounds like the pressure plate is weak.

You barely have to touch the pedal, does seem like the pressure plate.

I have to agree, it does seem like I've been really unlucky and ended up with a faulty or weak Pressure Plate. Its all very well them replacing it under warranty, but its going to cost me £240 to get it changed, which I can't help feeling they should pay! The other option is I do it myself but after the last time I vowed I'd never do it again, I dropped the gearbox to do it last time and it nearly killed me! but it was the easier option doing it on a mates drive, my drive is on a gradient and not suited to such a big job, and unfortunately my mate has since moved!

puppysandwich said:

I have to agree, it does seem like I've been really unlucky and ended up with a faulty or weak Pressure Plate. Its all very well them replacing it under warranty, but its going to cost me £240 to get it changed, which I can't help feeling they should pay! The other option is I do it myself but after the last time I vowed I'd never do it again, I dropped the gearbox to do it last time and it nearly killed me! but it was the easier option doing it on a mates drive, my drive is on a gradient and not suited to such a big job, and unfortunately my mate has since moved!

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Sounds like youve been unluck but as its 3 months out of warranty you cant really expect them to pay for fitting. I think your lucky they have offered to replace the clutch.

I would normally agree, but if they admit that the clutch was faulty when purchased, ie a manufacturing or materials fault then, surely they should be liable for any costs incurred as a result. I'm not going to pursue this but was just wondering how others might see it.

puppysandwich said:

I would normally agree, but if they admit that the clutch was faulty when purchased, ie a manufacturing or materials fault then, surely they should be liable for any costs incurred as a result. I'm not going to pursue this but was just wondering how others might see it.

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its normally only parts that are guarenteed ,unless they fitted it poorly

I understand that, I guess I'm just peed off that as a result of them selling me a Faulty clutch, I have to pay labour costs again to get it replaced..

puppysandwich said:

I understand that, I guess I'm just peed off that as a result of them selling me a Faulty clutch, I have to pay labour costs again to get it replaced..

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Well until it comes out you dont know that it is a faulty clutch.
Does it only do it in 3rd gear?

No, it does it in all gears, its just more noticeable in 3rd.