Diesel Clutch Problem

Synchromesh · 8th July 2012, 18:53

Gear selection became notchy then pedal resistance decreased then pedal wouldn't return. Bleeding temporarily fixed problem then it came back. Left master cylinder in situ but removed piston. Cleaned cylinder bore and piston. Reassembled and bled. Several lumps of grey grease found in bled fluid. Pedal really good for a few minutes then problem returned.
What is the grey grease?
Is main seal the grey plastic sleeve or the black rubber ring?
If worn seal is causing problem why is pedal really good when first bled?
Is a repair kit available?

Mike Noc · 8th July 2012, 19:05

When you first looked at the master cylinder was there fluid in the reservoir?

After you bled it and it started to fail again was there fluid in the reservoir?

Any signs of leaking fluid either around the master cylinder or underneath from the two holes where the engine meets the gearbox?

Mike

Synchromesh · 8th July 2012, 19:30

Quote:

Originally Posted by Mike Noc

When you first looked at the master cylinder was there fluid in the reservoir?

After you bled it and it started to fail again was there fluid in the reservoir?

Any signs of leaking fluid either around the master cylinder or underneath from the two holes where the engine meets the gearbox?

Mike

I must admit I haven't taken the engine under tray off yet to see if fluid is leaking from the slave. I think the dealer fitted a new slave before I bought the car. There is still fluid in the reservoir when the pedal drops to the floor.

Mike Noc · 8th July 2012, 20:00

I wouldn't worry about the grey grease - may have been added during assembly. Think the main seal will be the black ring and AFAIK a repair kit isn't available.

To test the master cylinder try bleeding it then disconnect the coupling where it meets the slave cylinder pipe (below the battery box) and try pushing it down. If the pedal sinks then the seals or cylinder bore have gone, and if it is rock hard then the fault lies elsewhere.

Mike

Synchromesh · 11th July 2012, 17:10

Took engine undercover off and confirmed clutch fluid dripping from bell housing. Fitting new slave and master this weekend.

Mike Noc · 11th July 2012, 20:21

Sorry to hear that Synchro. Most of us have been there....some more than once.

Mike

8th July 2012, 18:53	#1
Synchromesh Gets stuck in Rover 75 Saloon Join Date: Jan 2010 Location: Preston Posts: 626 Thanks: 50 Thanked 44 Times in 32 Posts	Diesel Clutch Problem Gear selection became notchy then pedal resistance decreased then pedal wouldn't return. Bleeding temporarily fixed problem then it came back. Left master cylinder in situ but removed piston. Cleaned cylinder bore and piston. Reassembled and bled. Several lumps of grey grease found in bled fluid. Pedal really good for a few minutes then problem returned. What is the grey grease? Is main seal the grey plastic sleeve or the black rubber ring? If worn seal is causing problem why is pedal really good when first bled? Is a repair kit available?

8th July 2012, 19:05	#2
Mike Noc This is my second home Rover 75 CDT Manual Connoisseur SE, Rover 75 CDT Automatic Connoisseur SE & a Freelander Td4. Join Date: Jul 2009 Location: Hampshire Posts: 11,578 Thanks: 3,470 Thanked 3,119 Times in 2,247 Posts	When you first looked at the master cylinder was there fluid in the reservoir? After you bled it and it started to fail again was there fluid in the reservoir? Any signs of leaking fluid either around the master cylinder or underneath from the two holes where the engine meets the gearbox? Mike

8th July 2012, 20:00	#4
Mike Noc This is my second home Rover 75 CDT Manual Connoisseur SE, Rover 75 CDT Automatic Connoisseur SE & a Freelander Td4. Join Date: Jul 2009 Location: Hampshire Posts: 11,578 Thanks: 3,470 Thanked 3,119 Times in 2,247 Posts	I wouldn't worry about the grey grease - may have been added during assembly. Think the main seal will be the black ring and AFAIK a repair kit isn't available. To test the master cylinder try bleeding it then disconnect the coupling where it meets the slave cylinder pipe (below the battery box) and try pushing it down. If the pedal sinks then the seals or cylinder bore have gone, and if it is rock hard then the fault lies elsewhere. Mike

11th July 2012, 17:10	#5
Synchromesh Gets stuck in Rover 75 Saloon Join Date: Jan 2010 Location: Preston Posts: 626 Thanks: 50 Thanked 44 Times in 32 Posts	Took engine undercover off and confirmed clutch fluid dripping from bell housing. Fitting new slave and master this weekend.

11th July 2012, 20:21	#6
Mike Noc This is my second home Rover 75 CDT Manual Connoisseur SE, Rover 75 CDT Automatic Connoisseur SE & a Freelander Td4. Join Date: Jul 2009 Location: Hampshire Posts: 11,578 Thanks: 3,470 Thanked 3,119 Times in 2,247 Posts	Sorry to hear that Synchro. Most of us have been there....some more than once. Mike