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PeteCrenshaw

Member Since: 05 Aug 2021
Location: Perth
Posts: 14

2006 Defender 110 2.5 TD XS CSW Chawton White

Removing clutch pedal box from Def Td5 with air conditioning

Need to replace my clutch master cylinder since it's been leaking onto the floor mat for quite a while. The biggest headache seems to be removing the pedal box. Has anyone achieved this on a RHD Td5 with air conditioning?

There is an annoying sill/panel/tab that hooks in the sound insulating trim. I'm not really sure how I'm supposed to remove it since there is the air con unit right in front of the 4 screws that hold it in place. I've attached a photo of one without the air con...

Click image to enlarge

Would I need to remove the whole air conditioning assembly to get at these? And how involved is that? Or can the air con just be slightly moved out of the way without discharging it?

13th Jun 2022 3:32pm

PeteCrenshaw

Member Since: 05 Aug 2021
Location: Perth
Posts: 14

This tab also definitely needs to be removed, since it obscures the top two bolts of the pedal box.

13th Jun 2022 3:33pm

Hufflepuff

Member Since: 25 Oct 2014
Location: Hampshire
Posts: 723

Yes I did it a couple of years ago. My memory is a bit hazy on how I did it - I have a vague memory of undoing the air-con outlet unit bolts on the right hand side and bending it down a bit to give the required access. I certainly did not discharge the air con loop to do it. 2005 Td5 90 XS
1989 V8 110 CSW

13th Jun 2022 3:48pm

PeteCrenshaw

Member Since: 05 Aug 2021
Location: Perth
Posts: 14

Thanks mate

I'll give that a go then! I also noticed I can get to the most obscured screw by taking out the speaker in the aircon.

13th Jun 2022 3:51pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5427

2006 Defender 110 Td5 USW Zermatt Silver

Done it a couple of months ago without removing the AC ratchet spanner and loads of foul language.

13th Jun 2022 9:36pm

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