My 1993 Discovery 200Tdi has developed a clutch fault. I’ve fitted a new Borg and Beck clutch and replaced the master cylinder, the slave cylinder and the connecting pipe.
It works fine for a week or so, but after that I have to bleed the clutch because the pedal goes to the floor with no clutch actuation. When I first bought the Discovery, its master cylinder was leaking into the cab, but I can’t see any sign of fluid leaks in the system now.
What’s the likely cause?
Graham Lynn, Diss, Norfolk
The problem is purely hydraulic, and air is getting into the system somewhere. You’ve fitted a good-quality clutch, but are the master and slave cylinders up to the job? There are some cheap pattern parts out there that have weak, leaky seals from new. Check the pipes, hose and cylinders very carefully, and make sure all the unions are tight. A small leak can allow air to be drawn in with little sign of fluid leaking out.