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  #1  
Old July 29th, 2009, 06:56 PM
John_Karlsson
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John Karlsson
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Clutch Died

D-90, 200Tdi, LT77/LT230. I was driving along happily, and suddenly I couldn't select gears. Pedal feels normal, so I don't think it's a hydraulic problem (BTDT). I didn't hear any expensive noises, just lost the ability to select gears. I can stop the engine, select a gear, start and drive, but I can't select gears without declutching, as I did when the hydraulics died, but that was with another gearbox. I can come to a stop in gear, but the clutch doesn't release completely.

Looking for a diagnosis.
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  #2  
Old July 29th, 2009, 08:43 PM
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Probably broke the release fork thing.
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  #3  
Old July 29th, 2009, 08:47 PM
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Can select any and all gears when stopped?
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  #4  
Old July 29th, 2009, 09:22 PM
John_Karlsson
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John Karlsson
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I didn't try every gear, but the ones I tried all worked, so I don't think it is a gearbox problem.
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  #5  
Old August 3rd, 2009, 01:07 PM
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I just got a call from the local mechanic, who probably has never worked on a Defender before. He agrees that the problem is probably the release fork, but he wants to know the best way to get to it. Does he need to pull the engine, transmission, or both?
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  #6  
Old August 3rd, 2009, 01:13 PM
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Either engine or transmission, but I have not done it myself on a 200tdi so I don't know what is easier or if there is another way. Personally, I would pull the motor, but that is just me.
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  #7  
Old August 14th, 2009, 03:49 PM
John_Karlsson
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John Karlsson
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Is there a common (in the USA) pilot shaft that would fit the 200 Tdi/LT77?
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  #8  
Old August 14th, 2009, 04:28 PM
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What is a pilot shaft? What is broken exactly?
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  #9  
Old August 14th, 2009, 05:08 PM
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It could be the little plastic clip that connects the clutch slave cylinder to the fork. Pull the slave cylinder and look in with a light (and mirror) to see if the clip is still on the fork.
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  #10  
Old August 14th, 2009, 06:22 PM
John_Karlsson
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John Karlsson
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Pilot shaft=clutch alignment shaft. I ran into the mechanic today, and he was talking about making a shaft. If I could tell him a common equivalent, he would probably already have one on hand.

I stopped by to have a look after he got the transmission moved back. The release fork is in good shape and had been heavily reinforced. The diaphragm spring on the pressure plate looks flat, not raised, but he hasn't yet removed it to see what's wrong. All parts are in hand so it's just a matter of repairing the US Mail truck that bumped me down on the priority list.
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  #11  
Old August 24th, 2009, 06:35 PM
John_Karlsson
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John Karlsson
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Just got the Rover back. I was pretty sure it was going to be the release fork, but it turned out to be the clutch disc. The lining was in great shape and firmly attached, but one of the rivets that hold the metal "sandwich" together had apparently come loose, so the sandwich started to separate, and the little coil springs were flopping around. The shop owner said he had never seen one do that before.
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