bankz5152

Well-Known Member
Defender Clutch Spring Replacement

Did the clutch spring mod today and found it extremely difficult to get the spring into it’s the various bushes, even after reading the various guides online. Most of which over complicated the procedure the rest were not very helpful. So I decided to write this up based off how I did it, which If I were to do it again would be much easier!

You will need the following –

EDP7510L
DCP3212L
CLP3180

Ebay Item number - 321597948655 - Thats for the kit

Step 1
Pop the bonnet and locate the clutch pedal box and loosen the adjustment bolt* at the bottom until its almost completely out. This allows the clutch pedal to be pushed right to the floor.



Bolt 17 is the one to be loosened off

Step 2
Remove any interior trim surrounding the pedals if you have it.

Step 3
Remove the current spring, one bolt at the top of the spring. Replace the bolt when done

Step 4
Fit all the bushes. You should have 3 in total, x2 circular ones and one U Shape



Step 5
Fully depress the clutch and wedge in place with a piece of wood, stick anything that will fit, you want the clutch pedal as close to the floor as possible. Then push the spring into the U-Bush. (make not of how from the above pic)

Step 6
Here is where it gets a bit tricky. Start with whichever side you like or whichever is easier to push down. The aim is to get the prongs on the spring into the circle bushes. Quite a lot of pressure is needed but it can be done.

On the first try it may not seat in fully but rather get stuck, this is fine as the spring is now under some tension. It should be much easier to push the opposite side into the bush. Which on the first attempt should pop straight in. Now try and get the other side in, bit of giggling and it was in.



Step 7
Replace everything you removed and don’t forget to screw the pedal adjustment bolt back in!


Hopefully this helps anyone trying to do this mod, which I highly recommend.

Any comments/additions are welcome

Josh.
 
Please ignor my text below - I googled the number provided and realise it's to lighten the pedal pressure on TD5's. Not suitable for my 300 TDi.



Apologies for my ignorance because I wasn't aware that a modification existed to the clutch pedal - what is the benefit having done this? The reason for asking is that for some months I had a squeaky clutch pedal which appears to have cured itself after extensive spraying with whatever lube I had, but incase it returns and have to dismantle it all, I may want a possible additional benefit.
 
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i looked at these spring assist kits a while ago and iam thinking with a little adjustment they could be fitted to a 300tdi, its renewed my curiosity.
do they help much? might have a go at fitting to my 300 if they work.
 
i looked at these spring assist kits a while ago and iam thinking with a little adjustment they could be fitted to a 300tdi, its renewed my curiosity.
do they help much? might have a go at fitting to my 300 if they work.

it should require no tweaking, these are standard replacement parts and i think you should already have it on a 300tdi. they seemed to have went back to the single long spring for some td5's though.. dunno why
 
i looked at these spring assist kits a while ago and iam thinking with a little adjustment they could be fitted to a 300tdi, its renewed my curiosity.
do they help much? might have a go at fitting to my 300 if they work.

They do make a difference mate.
I fitted a td5 pedal box to my brothers old 200tdi 90 and couldn't believe the difference.
Was only fitted as his master cylinder was weeping, had a complete pedal box in the shed so fitted that, so was win win for him and it didn't cost him anything.
 
Why go through all the hassle to fit the spring with the pedal in the vehicle when it only requires the removal of 6 bolts to remove the complete pedal box from the vehicle and work in comfort on a bench?
 
According to LR the mounts have been in place since 1987! The only parts to buy are the above.

It is well worth doing, Defender is a treat to drive now.
 
single long spring on my '96 300 dont find mine too heavy, it got alot lighter when I did the clutch last year.
might have a nosey at it tho.
 
holy thread ressurection.

Me knee is rapidly giving up. Will this mod work on a 1991 2.5na ex-military (although now tdi)?
 
holy thread ressurection.

Me knee is rapidly giving up. Will this mod work on a 1991 2.5na ex-military (although now tdi)?

This was discussed just last week, with a few pics thrown in. I suppose it depends on what clutch pedal you have at the moment. If you have the right pedal there is someone on line selling the spring kit for £15.

Cheers
 
This was discussed just last week, with a few pics thrown in. I suppose it depends on what clutch pedal you have at the moment. If you have the right pedal there is someone on line selling the spring kit for £15.

Cheers

Got a thread link? I didn’t see that sorry
 
holy thread ressurection.

Me knee is rapidly giving up. Will this mod work on a 1991 2.5na ex-military (although now tdi)?

You could always fit a servo .... I did this on SWMBO's D1 - pedal effort down from 18Kg to about 9Kg IIRC - I.E. you can disengage the clutch with finger pressure :) .... although I must point out that forward vision is limited in so doing :D

I even did a thread on it too ;)
 
Put it in a vice. Cable tie both sides. Insert. Cut cable ties. Done. 3 mins.

S

Thanks Bankz5152 for the instruction and I reckon bigfasti's tip saved me a load of time, a great deal of swearing, and shredded finders. I've just done this taking about 30 minutes in all. The difference to my TD5 Defender 2002 is astonishing - It's much lighter on the left leg meaning all that effort (especially in traffic) was just pointless wasted energy. Well recommended. Using the cable ties means you can locate the 2 side spring ends into their holes first, and then when you cut the cable ties the centre loop springs right into place on the back of the clutch pedal. You also don't need to do any of the dismantling, adjusting, and blocking of the pedal to the floor - everything is in the right place as it is.
 

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