Hi guys.

I have a 2003 Discovery TDi and love the damn thing to bits but recently I have been having a few issues.

Biggest by far is the clutch.

So far I have had the full clutch, master and slave cylinders and hydraulic pipes renewed and I still dont have a clutch I can use.

Symptons are the pedal is there at first but goes completely when the engine is revved up at all.

I can bring the clutch pedal back to life with several pumps but only when the engine is either at idle or switched off...

Any suggestions as the guy doing the work now wants to replace the dual mass flywheel as there seems to be no other solutions.

I have no issues if this cures the fault but would like to see what you guys think....

I did a search of the forum before posting this but couldn't find anything close to this issue.

 

I PMed you.

 

Sounds like there is air in the system. There really isn't any adjustment for the clutch.
They can in fact be a pain to bleed.
Here are the steps.
[IMG]local://upfiles/7701/7EE44BE100D74392AA52BB38F11968A3.jpg[/IMG]

 

Ok, got the car back two days ago and it is pretty damn near perfect.

garage has now changed the flywheel which I must say, on inspection had a great deal of wobble in it.

Goes back in tomorrow to have the original master cylinder fitted as it appears this was never at fault.

It would seem that as a general rule of thumb, the flywheel should be changed with the clutch every time.

The trouble is that the clutch itself was actually fine, the only faulty thing was the slave cylinder but it needed a whole clutch and flywheel to rectify this.

The original thrust bearing showed signs of uneven wear on one shoulder where it meats the fork, this I now believe was as a result of the flywheel vibrating in and out, though no vibration was felt. When this wear reached a critical point the clutch pedal failed or the flywheel had even greater wobble, either way we had no clutch pedal at all - strangely enough though, when the pedal went to the floor their was no apparent fluid loss and I could still feel the pressure plate spring levers rubbing against the thrust bearing through the pedal so some contact was still being made.

Had I bled the clutch I think I could have got the pedal back up but this would have failed again as soon as the engine revved and the flywheel wobbled.

I hope this has given a bit of an insight into this issue and thank you all for your contributions and help.

I'll let you know if the car is still ok when the original master cylinder is refitted...

 

We are waiting!
________
Tuareg 350

 

Sorry bonnettoboot.

I have had the original master cylinder fitted back on and the clutch is damn near perfect.

The lesson to be learned here is if you need the clutch replacing then consider doing the flywheel at the same time.

So the Disco is back on the road and running great, all I need to do now is fix my Patrol and wait for the snow!!

Thanks for all the advice guys..