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Appleby



Member Since: 03 Apr 2012
Location: Bristol
Posts: 74

United Kingdom 2002 Defender 90 Td5 CSW Epsom Green
Clutch Problems
Hi everybody!

My 02 Td5 has just ticked over 100k miles and started to develop the first ever issue I've had with it.

The clutch is sticking when fully depressed and I can't get it in or out of gear. If I pop the pedal back up using my foot I can then get it in and out of gear. The gear changes can be really stiff too.


If I sit with the clutch pedal pressed and in gear with the brake pedal pressed hard.,the clutch will slowly engage and stall the engine. Does this sound like symptoms of a leaky clutch cylinder? Can I just dump some more DOT4 in there to get me 30 miles over the weekend?
Post #661181 1st Nov 2017 4:03pm
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Mash



Member Since: 09 Feb 2015
Location: Guernsey
Posts: 1674

Guernsey 1998 Defender 90 300 Tdi HT Nato Green
Yea topping up should be fine Thumbs Up

Most likely be the slave cylinder leaking which is an easy job. 90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html
110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html
52HG25 lightweight https://www.defender2.net/forum/topic72342.html
D3 Hse - Fiona
Capri 2l S - Anna

Think I might have a problem............
Post #661183 1st Nov 2017 4:21pm
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TechnoTurkey



Member Since: 25 Jul 2016
Location: Worcestershire
Posts: 88

2005 Defender 110 Td5 CSW Zambezi Silver
Easy apart from bleeding it!
Post #661402 2nd Nov 2017 12:28pm
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Vogler



Member Since: 02 Nov 2014
Location: Brussels
Posts: 309

Belgium 2015 Defender 110 Td5 HT Chawton White
Use reverse bleeding. Introduce DOT4 from below using a large syringe and make sure to get some out of the reservoir so it doesn't spill.
Also, it apparently helps to get rid of the air by keeping the pedal depressed for a night.

Greetings,

Joris
Post #661404 2nd Nov 2017 12:34pm
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DieselBeast



Member Since: 27 Sep 2017
Location: UK
Posts: 33

1998 Defender 90 300 Tdi PU Java Black
Is the Td5 clutch slave cylinder the same external type as the 300 tdi?
Post #661518 2nd Nov 2017 8:50pm
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Low-Range



Member Since: 30 Sep 2016
Location: BC
Posts: 41

Canada 
old school oil can
You can also use the old school oiling can with a little flexible tube to push up fluid...no air trapped in line.

AND IT"S CHEAP
Post #661544 2nd Nov 2017 10:04pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: South West
Posts: 4554

DieselBeast wrote:
Is the Td5 clutch slave cylinder the same external type as the 300 tdi?


clutch slave cylinder in TDI engines

ftc 3911 To V TA 9975715 + FRC2402

ftc 5072 to G 56A 0669086K + FRC2402

ftc 5202 from G 56A 0669086K + FRC2402

clutch slave cylinder TD5

FTC 5202 TD5
Post #661586 3rd Nov 2017 8:01am
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lightning



Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2159

United Kingdom 
After you've fitted new parts and bled the system, you will most likely find that no matter how much you bleed/reverse bleed it, the clutch engages right at the bottom of the pedal.
Wedge the pedal down overnight and that should sort it.
Post #661723 3rd Nov 2017 8:24pm
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williamthedog



Member Since: 29 Dec 2012
Location: south wales
Posts: 3441

2011 Defender 90 Puma 2.4 PU Tamar Blue
Just what you had to do with
the old minis
Post #661735 3rd Nov 2017 9:24pm
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LinDens90XS



Member Since: 24 Feb 2012
Location: Merseyside
Posts: 83

2003 Defender 90 Td5 XS CSW Bonatti Grey
My penny worth. It may be just as well to change the master at the same time as when one goes the other is never far behind. Regards
Dennis.
Post #662930 9th Nov 2017 9:21pm
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Oakseywick



Member Since: 20 Dec 2014
Location: Cirencester
Posts: 1000

United Kingdom 2000 Defender 90 Td5 XS CSW Java Black
I recently had a new clutchfix HD1 clutch and valeo dmf fitted I have noticed bitepoint very low to floor but also that the pedal has drop a inch or so and does return right to top position. You can move the pedal up a bit with your foot, any advice? Would this be sorted by wedging pedal down over night as lightning suggests Question
Post #662960 9th Nov 2017 10:24pm
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agentmulder



Member Since: 16 Apr 2016
Location: Outer Space
Posts: 1324

Kuwait 
Never tried this but next time I will..

So I thought to catch air bubbles in the line from the syringe/oil can install a t-joint with a short section of terminated hose at the apex of the hose. Thumbs Up Solved the bowel problem, working on the consonants...
Post #662966 9th Nov 2017 10:36pm
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lightning



Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2159

United Kingdom 
Oakseywick wrote:
I recently had a new clutchfix HD1 clutch and valeo dmf fitted I have noticed bitepoint very low to floor but also that the pedal has drop a inch or so and does return right to top position. You can move the pedal up a bit with your foot, any advice? Would this be sorted by wedging pedal down over night as lightning suggests Question


Try it tonight and see! It has always worked for me.
Post #663118 10th Nov 2017 2:03pm
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4RF RDS



Member Since: 19 Jul 2015
Location: Ottawa
Posts: 890

Canada 2000 Defender 110 Td5 XS CSW Epsom Green
Defo sounds like you’ve got a slave or master leak. Check fluid level, fill and bleed then determine what is leaking and replace or rebuild. 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)
Post #663141 10th Nov 2017 3:33pm
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