At least once during every journey my 200Tdi Defender 110’s clutch pedal will only go down a third of the way, just enough to change gear. At that point the pedal goes solid and won’t be forced down further. After a couple of attempts it returns to normal. The clutch was new two years ago, along with the thrust bearing. I’ve changed the master and slave cylinders, because I had spares, but this has made no difference. I did weld a plate behind the pivot point when I changed the clutch. What do you think?
Ivan Grova, Market Drayton, Shropshire
Because you’ve replaced the master and slave cylinders it’s unlikely to be these, so it’s either the arm and pivot or release bearing. Whichever it is, you have to split the engine from the gearbox. Hopefully the problem will be revealed. Replace the release arm and release bearing anyway and check the pivot ball; the case hardening can peel off, leaving a very rough surface that will quickly eat through the new arm.
This workshop advice appeared in the August 2014 issue of LRO. Back issues are available to download on digital devices here.
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