Help, clutch problem!

[Rich]

Hi all, have been doing some much needed work on the TD van I have, and have run into a problem.

I started with replacing the CV joint, then got big and brave and decidd to replace the slipping clutch. All was going so well, new (well good second hand clutch) has been fitted and all is back together. Decided to replace the cable, as the old one had been "modified" with a jubilee clip holding the self adjusting spring further back the clip does. Tried the new clutch cable, and the pedal was all floppy, and had loads of free play in it. It was only just touching the clutch when it was right down.

Put the old cable back on, and after further inspection, the rubber bush on the gearbox end has had an extra lump of rubber added to it. Anyway, re-fitted the old one, and I still have free play, and floppy pedal. I am going to try putting the jubilee clip back on, but is there somthing obvious I am missing here?

I can operate the clutch arm by hand, and can feel the clutch is working, I just can't get the pedal to work it!!

[a35mad]

If it is any consolation, my TD car has a clutch that works fine and a cable that appears unmodified, but there is a mass of floppiness at the pedal, like free travel but in reverse, the pedal sits well down and can be lifted quite a bit.

[Rich]

Its not that much of a consilation, this is how this one is supposed to be!!! However, I have tried putting the jubilee clip back on, and that made a little difference, however, on attempting to engage a gear, i just wouldn't. So I gave the cable an almighty tug at the pedal end where it goes into the cone shaped thing, and all was well! It goes like stink with a new clutch and actually pulls away!

Thing is, the problem has quickly come back, and now the gears are hard to engage. When you pull at the cone, it is ok for a few pushes, then it slips back and is har to get the gears......:banghead:

[countrydude]

I had this after changing the clutch, I posted and got the classic haynes manual reply: pump the pedal and hear a ripping sound which is the cable setting itself. Not a chance!!

I ended up fitting it and then twisting the black plastic self adjusting slider?? near the bulkhead. I found it would move along the threads and I could manually adjust. It has been fine since.

I bit odd though, a non self adjusting cable?? At least we are not alone!!

[E_T_V]

Sounds like a duff self adjuster, i.e a duff cable. Also make sure the cable routing is correct as if it isn't the clutch operation goes to pot.

[Rich]

After a lot of swearing, jumping up and down, and throwing tools around the workshop, a new cable this morning has sorted it. Self adjuster indeed:rolleyes:

It has to be said, there is nothing worse than the feeling of "i'm going to have to take that gearbox I have just put back on, off again...."

Thanks, Rich