Clutch not releasing

[donb]

I've been racking myself on this for the last week or so.

The setup is:

- 200tdi going to a LT77.
- UQB000130 - HD Clutch Disk
- PLE223HD - HD Throw Out bearing
- PLH534 - Pressure Plate (Valeo)
- PLC535 - Slave Cylinder
- stock pushrod and fork used
- SDO Dorman master kit

Weeks ago I got the 200tdi bolted onto the LT77 which was a bit of a fight. Recently when I went to bleed the clutch after I felt good pressure I tried pushing the clutch in and spinning the output on the LT230 while in gear (the floors are out so I could easily access). The LT230 flanges was locked with the engine.

I had to pull the 1.6 out for a 1.4 swap. Pull the transfer case and tried with the out put for the tranny. Same thing - pedal feels good with pressure after bleeding again but out put locked with engine while clutch is in.

Pull the LT77 as maybe the fork and throwout bearing got moved when originally installed. Pulled apart, reset everything put back tranny back to the 200tdi. Same thing.

So I pulled the slave and clamped the pushrod in as far as it would go. Same thing gearbox shaft locked with engine.

Pull the tranny again. Pull pressure plate and clutch (which came right off). Cleaned flywheel surface (which was originally machined). Bench tested pressure plate and it would release with not that much movement on the hydraulic press. I set it up with the friction plate underneath and the friction plate moved freely when the teeth were pushed in. Reinstall the LT77 again. Clutch pressure felt good but still wouldn't move with clutch in. Bled again, same thing.

Output shaft on all tests would not budge with 2 hands on it trying to twist.

Any help will be very appreciated.

 

[1of40]

I had problems with the HD throwout bearing on a r380 once and had to chuck it for standard.

 

[donb]

I had problems with the HD throwout bearing on a r380 once and had to chuck it for standard.

Interesting. I was thinking of swapping the HD throwout with one of the standard ones I have on the bench. I'm not sure why that would make a difference as the height and pivot spot are the same but might be worth the test to see.

 

[Adam]

did you replace/upgrade the clutch fork? I replaced my master only to have the clutch fork blow out while bleeding.

My Heavy Duty Clutch Fork

Possibly the best clutch modification for the 4 cylinder Land Rover engines? Fits 1983 onwards (NOT V8 or any Series):- 2.25 Petrol 2.25 Diesel 2.5 Petrol 2.5 Diesel 2.5 DT/TD 200Tdi 300Tdi This is…

britrest.com

 

[donb]

did you replace/upgrade the clutch fork? I replaced my master only to have the clutch fork blow out while bleeding.

My Heavy Duty Clutch Fork

Possibly the best clutch modification for the 4 cylinder Land Rover engines? Fits 1983 onwards (NOT V8 or any Series):- 2.25 Petrol 2.25 Diesel 2.5 Petrol 2.5 Diesel 2.5 DT/TD 200Tdi 300Tdi This is…

britrest.com

I don't have that type of clutch fork but welded a plate on one I had. When testing with a clamp to see if the pressure plate was working I actually bent the end of the clutch fork and not poke thru the middle. I had yet another clutch fork with a welded plate that I used yesterday.

 

[Z.G]

I don't have that type of clutch fork but welded a plate on one I had. When testing with a clamp to see if the pressure plate was working I actually bent the end of the clutch fork and not poke thru the middle. I had yet another clutch fork with a welded plate that I used yesterday.

You dont have that type as in the HD, or you have a cast one?

For whatever reason I had a lengthy experience bleeding the dorman clutch master, not sure if it's related.

 

[donb]

You dont have that type as in the HD, or you have a cast one?

For whatever reason I had a lengthy experience bleeding the dorman clutch master, not sure if it's related.

I don't have the Britrest one with the plastic bushing (they look really well built and if I had time I'd order one of the DIY kits).

I am using a run of the mill steel one with a plate welded on the outside of the middle pivot. I didn't know LR made a cast version of it.

I was wondering if the Dorman master might be pretty tricky to bleed during one of the processes. I might do another clamp process and see if I can release the pressure plate without using the slave. I have an old slave that I should be able to measure the throw length.

 

[donb]

Got it to release.

I'm not sure what it was but here is what I did:

- had an LT77 box laying around. Broke it down to the bellhousing and middle section and input shaft. Cut out a section of the bellhousing to see the insides.
- installed the fork, throwout bearing and pivots then used the "mock" tranny to the 200tdi
- installed the slave that I thought was bled and tested it out. Worked fine and cool to see the movement thru the bellhousing.
- took off the clutch and pressure plate and this time I aligned with the input shaft from the mock. Making sure it went in smoothly.
- took the full LT77 and reinstalled this time it went on much more smoothly than the other times I had it off.
- re-installed the slave and tested it and it works great.

Maybe each time on install the pivots, forks or throw out bearing was getting moved from the input shaft not sliding in easily and then not engaging the pressure plate correctly? Maybe the plastic line up tool had the clutch not centered enough and something was binding on install?

I don't know for sure but very glad things are working smoothly now.

I was going to attach videos but no place to host. If anyone wants one please DM and I'll send.

 

[Napalm00]

Nice!

 

[donb]

Nice!

Nice when it was spinning with the clutch depressed. Taking that LT77 in and out 3x wasn't so nice haha. But very glad I kept with it before sticking the 1.4 LT230 onto it. It might have "broken" whatever the bind was but if it didn't...

I'll keep that input shaft for the future if anyone needs to borrow to line up clutch plates.