R380 Clutch/Master/Slave Problem - Defender Source
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  #1  
Old October 28th, 2013, 08:51 PM
Lee
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Lee O
95 NAS D-90 300Tdi
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R380 Clutch/Master/Slave Problem

Hi All -

Looking for some help diagnosing my clutch problem. My master developed a leak so i took it to my local guy and supplied him with a new master. He replaced it and it worked but didn't have the same throw/release points (needed to be closer to the floor). A couple days later, the clutch stopped working all together. I had a couple inches of throw that should have been left but when i pressed the pedal there, it did not release the clutch.

I've moved on from him and a read of the various threads suggests it could fall somewhere between a bad bleed to a broken fork/throw-out bearing. Obviously I'm hoping for the former.

Attached are a couple pics of the bell housing with the slave removed (sorry, pics are upside down). Does the slave pin look like it's in the right position (should it be proud of the bell housing when released)? Also, the slave pin has some play when I try to move it back-and-forth.

Truck details are 95 NAS w/ 300Tdi conversion.

THANKS!

-Lee
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  #2  
Old October 28th, 2013, 09:55 PM
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Robert Davis
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Look fine from what can be determined by the pictures,
The master cylinder is adjustable.
Was it adjusted out near the end?
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  #3  
Old October 28th, 2013, 11:43 PM
Lee
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Lee O
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OK, I'll pull the master to see what that looks like. Thx for the feedback.
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  #4  
Old October 29th, 2013, 12:13 AM
Bolson
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Ben Olson
1995 Defender 110
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when my clutch fork let go in my 110 it just sort of slowly failed ( the fork cracked almost all the way around the pivot socket ) and when it finally punched through the clutch was like stepping on a brick if your fork is going , the pedal seems to change too
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  #5  
Old October 29th, 2013, 06:14 AM
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John B.
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Quote:
Originally Posted by Lee View Post
OK, I'll pull the master to see what that looks like. Thx for the feedback.
Slow down. They are simply suggesting to check the adjustment at the master. No need to pull it out.
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  #6  
Old November 3rd, 2013, 11:43 AM
Lee
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Lee O
95 NAS D-90 300Tdi
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OK, so I have adjusted the pedal and master as described in the attached pic. I then bled the system pushing fluid from the slave to the master. The slave was removed from the bell housing, hanging from the hose so air would be pushed up the hose after filling the slave. Once I had fluid in the master, I reinstalled the slave (this was a PITA to get the push-rod in the slave) and topped off the master. As you can see from the two pics, the pedal when free is 5.5" (~140mm). The problem is when I step on the pedal I get about 1.25" of throw and then it is firm and I can't push it any further.

So I now have the same problem as before but the pedal stops moving further from the floor.

It does seem that the master push-rod was incorrectly adjusted and that was the reason for the short throw.

Thx

-Lee
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  #7  
Old November 3rd, 2013, 03:13 PM
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John B.
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Sounds like the slave push rod is not in properly.
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  #8  
Old November 3rd, 2013, 09:12 PM
Lee
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Lee O
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Thx John. So what would I do next?

Thx!
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  #9  
Old November 3rd, 2013, 09:32 PM
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John B.
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Take the slave off and look into the bell housing. Make sure the push rod is sitting properly on the fork. Also make sure the fork is not broken as they do punch through at the pivot.

Actually, looking at you pictures in the first post, I'm pretty sure the rod should be sticking out further, which points to a damaged fork. With the slave off, look around the corner a bit to see the pivot point.
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  #10  
Old November 4th, 2013, 12:17 AM
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Jason Zolezzi
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I agree with John on the push rod. It should be sticking out about an 1 1/2 if I remember correctly. The problem could be the throw out bearing too. Don't mess with the rod too much, you can yank it out of there. I know because I did it. If you do open it up just replace everything. Good luck, clutch issues can be frustrating.
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  #11  
Old November 4th, 2013, 08:13 AM
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chris
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yes from look at the pics the trans has to come out could be either fork ,pressure plate , throw-out bearing
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