Clutch stuck to floor - Defender Source
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  #1  
Old March 31st, 2010, 03:02 AM
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Brian
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Clutch stuck to floor

The other day I was stopped at an intersection and pushed the clutch to the floor with gear shift in First but nothing happened. Car was lurching forward and I had to use my foot to pull the clutch pedal back out. It's happened a few times in the last few days. Checked fluid level after each occurance and could tell it had dropped about 3/4" in the resevoir. Only added a few tablespoons to top it back of. No fluid under the pedal. What's going on here? Searched other threads but couldn't find a similar story. I'm not driving it right now because of another problem involving the ECU and stalling issues.
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  #2  
Old March 31st, 2010, 06:56 AM
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Slave cylinder is shot. It will come back temporarily if pumped.......although it is a challenge to get your hand under it to do that while driving. I get these in the shop frequently of late. Must be a duty cycle running it's course. I'd reccomend a full clutch hydraulic rebuild (master and slave and probably the soft line to the slave).
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  #3  
Old March 31st, 2010, 11:35 AM
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Search for the spring update.

You slave may or may not be hosed, but the spring modification has worked well enough for me.

http://www.defendersource.com/forum/...=clutch+spring
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  #4  
Old March 31st, 2010, 12:31 PM
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As long as the clutch fork didn't pass thru the lever, you're
on the safe side, changing both cylinders is not so easy
but it's not a nightmare. The master cylinder is a little
tricky because you have to take the hole assembly out
of the truck.
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Old March 31st, 2010, 12:46 PM
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I have had that happen to me too. pop it into neutral and pump the clutch a bunch and it should return to normal. mine did that twice in 4 month so its random and nothing major, but I would get after the slave cylinder when you can.

Also like Ron said, put another spring in there. There should be a be a tab with a hole at the top of the clutch. I drilled a small hole under the dash and ran a Series brake spring up to the whole and hooked it to the pedal. im sure Home Depot has a spring you can find to fit.
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Old March 31st, 2010, 02:07 PM
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Thanks for all the info. Are you saying add a second spring and that could fix this. THat doesn't sound right. Seems like if a second spring was supposed to be there it would already be there. Or do you think I should do the two easiest things first (Spring and slave) and maybe not have to do the master cylinder. I don't think I would attempt to do the master cylinder myself. I need an education on clutches.
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Old March 31st, 2010, 02:47 PM
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Do the spring for now as it should bring the clutch up if this happens again. but in the long run you will need to replace the slave.
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Old March 31st, 2010, 03:02 PM
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Quote:
Or do you think I should do the two easiest things first (Spring and slave) and maybe not have to do the master cylinder.
According to what you've written above I think the spring won't help. You got a leak somewhere and I suppose it's the slave. If the slave got broken it won't take that long and the master get's broken too. How does the fluid look like? Black and dirty? Put in a new hose too.
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Old March 31st, 2010, 03:51 PM
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sounds good. Thanks for the help. Seems like everythings going out at one time: water pump,alternator, ECU, and now needs clutch overhaul.
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  #10  
Old March 31st, 2010, 03:54 PM
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Do the spring now and see if it is better.

Like I said, probably a bad slave, but the spring makes them so much better IMHO.
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Old March 31st, 2010, 05:10 PM
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Sorry, but have you read the first posting of bd90?? He pushed the clutch to the floor and it did not open. If this had been a single case I'd say ok ignore it, maybe the bottom valve of the master was sticky. But this is a reocurring problem combined w/ loss of fluid. If this happens in the wrong situation it may extends the stopping distance for a few meters...
I would not make any experiments on this as the root cause seems to be clear. IMHO first thing is to remove the slave and take a look at it. I'm sure you will find the leak there
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  #12  
Old March 31st, 2010, 05:30 PM
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Like Ron said: http://www.roversdownsouth.com/series-brakes.htm part #569701.

Refer to the thread he pointed out a few posts up. I would probably top-up any loss in fluid too. I had the same problem last year at this time, and this was my quick fix for several weeks. I did end up putting in a new master and slave cylinder and that solved the issue. Do the work yourself; it's really not that bad.
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Old March 31st, 2010, 05:31 PM
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I did miss the bit about fluid loss which must mean a leak somewhere (either master, slave or line), but, in any event he should do the spring mod as well as replace everything (master/Slave AND line) and I would recommend genuine or lucas brand parts for the master and slave.

Ron
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Old March 31st, 2010, 10:06 PM
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replace it all. Its not hard.
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Old March 31st, 2010, 11:15 PM
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Rebuild the slave or just replace the whole unit. RDS has rebuild kit for @$12 and whole slave for @ $50 or 60 I think. If its easy to rebuild I'll just do that but if I have to fight with the seal removals and risk damaging it I'll just replace.
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Old April 1st, 2010, 01:19 AM
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Real easy to rebuild (like 5 minutes of work on the bench), you just have to make sure there are no pits or corrosion on the inside of the cylinder.

Me, I just replace and then rebuild the original and keep it as a spare.

Ron
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  #17  
Old April 1st, 2010, 07:29 AM
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The clutch hydraulics in a Defender are identical to a Series (different parts, but identical system).
In the 30+ years I've been working on Rover clutches I've found that it's better to just replace with new, unless you're on a really tight budget. A rebuild works sometimes, but as often as not, in my experience, it doesn't. To me it's enough of a pain to replace the units I only want to do it once.
If you have an old system, a 97 counts as old, definitely replace MC, SC and line if you replace either the MC or SC. If one is gone, the other will follow in short order if you only install one new.
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  #18  
Old April 1st, 2010, 01:42 PM
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Quote:
Originally Posted by huck1974 View Post
replace it all. Its not hard.
Okay, who wants to come help me change mine? I'm a bit concerned about getting the master out/in...
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  #19  
Old April 1st, 2010, 02:38 PM
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Yes, the more you do it (replacing master/slave) the better and easier it gets for you.
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  #20  
Old April 1st, 2010, 03:06 PM
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Quote:
Originally Posted by Neil McCauley View Post
Yes, the more you do it (replacing master/slave) the better and easier it gets for you.
said like someone who's done it at least 3 times... so how many have you done?
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