TCT Engine Clutch job

[andmcit]

Anyone done this and can offer pointers and tips that are specifically Activa orientated - what's the deal with the hydraulic clutch for example?

Andrew

[CitroJim]

The hydraulic clutch and the sheer size of the ML5 'box makes the job a bit more tricky Andrew but essentially it's a very similar job to doing a clutch in a lesser Xantia.

One has to take care when releasing the slave cylinder from the gearbox that the piston does not pop out. It is best secured with a few ty-wraps. If the piston pops out, hydraulic fluid leaks and its goodnight Vienna for the whle lot as the clutch hydraulic system is sealed and neither refillable or bleedable (as far as I know). Somehiow, I think one can recover it but officially you can't. A new hydraulic clutch kit (which includes master and slave cylinders, pre-filled and bled) is eyewateringly expensive and incredibly hard to fit.

Once again, like a TD clutch on a BE3, it's a "pull" clutch and the release bearing is attached to the diaphragm spring by a big "C" clip. The release bearing is firmly attached to the operating fork and not initially attached to the diaphragm spring like a 1.9TD bearing. On reassembly, the bearing has to be pulled into engagement with the diaphragm spring using a special tool that engages in the release arm and is smartly tugged backwards to pop the "C" clip in. The BoL covers it reasonably well in the gearbox section.

So, basically a 1.9TD job but with added fun! The same arrangement is used on the 2.1TD and 110 HDi.

[ACTIVE8]

The hydraulic clutch and the sheer size of the ML5 'box makes the job a bit more tricky Andrew but essentially it's a very similar job to doing a clutch in a lesser Xantia.

One has to take care when releasing the slave cylinder from the gearbox that the piston does not pop out. It is best secured with a few ty-wraps. If the piston pops out, hydraulic fluid leaks and its goodnight Vienna for the whle lot as the clutch hydraulic system is sealed and neither refillable or bleedable (as far as I know). Somehiow, I think one can recover it but officially you can't. A new hydraulic clutch kit (which includes master and slave cylinders, pre-filled and bled) is eyewateringly expensive and incredibly hard to fit.

Once again, like a TD clutch on a BE3, it's a "pull" clutch and the release bearing is attached to the diaphragm spring by a big "C" clip. The release bearing is firmly attached to the operating fork and not initially attached to the diaphragm spring like a 1.9TD bearing. On reassembly, the bearing has to be pulled into engagement with the diaphragm spring using a special tool that engages in the release arm and is smartly tugged backwards to pop the "C" clip in. The BoL covers it reasonably well in the gearbox section.

So, basically a 1.9TD job but with added fun! The same arrangement is used on the 2.1TD and 110 HDi.

Well citrojim that sealed clutch system might have suited Citroen for manufacturing purposes, but that sealed system seems like a strange idea to make it, so that it can't be worked on, repaired, and maintained as separate items!

It is as you say, also very expensive !!

I phoned a main stealer to find out more, and see just how expensive it is, it's not a normal stock item, so they probably don't go that often.

So here's the price, and I hope you are sitting down when you read this as it costs £390.97 + VAT !!

The parts man was surprised as he had not supplied one before, when he looked this hydraulic assembly up on his computer. He went and spoke to the workshop to make sure, because he couldn't believe that it did not come as separate components, and even he was surprised at the price.

P.S. Apparently only the pushrod comes as a seperate item.

Come on Citroen you should be able to do better than that !

I suppose that's in case it gets damaged, bent etc, but why could they not re-design the hydraulic operating system.

Imagine if the suspension had been designed the same way!!

[CitroJim]

So here's the price, and I hope you are sitting down when you read this as it costs £390.97 + VAT !!

I need a smily with its chin dropping to the floor to fully express my shock at that price

I wonder if Martin at Pleiades can refurbish them?

If your Stealers have never supplied one, they must be at least a reliable component. Fingers crossed as I have three cars with these clutches if I count in my son's 406 2.1TD...

The only bright side of it is we have no worries with the dread clutch clip that bedevil lesser Xantias.. Scant comfort though

[Spud]

[Sl4yer]

The number of things that can kill an Activa is quite frightening:

Front ram: £364.90
Rear ram: £340.41

Not to mention the 'bush' (or Articulation as Citroen call it!) at £169.54.

All inclusive of VAT by the way.

That Citroen Service site could keep you awake at night!

Interestingly, the Stealer's receipt shows that the rear ram on mine cost £267.83 inclusive, but is a Z part (not sourced from Citroen). Wonder who they get them from?

James

[handyman]

Hold on a minute there!

These supposedly sealed hydraulic clutch units can be refilled. All you need to do is take off the top of the reservoir, mount it so it is the highest point and administer fluid over a period of time. Any air bubbles will work their way north.

I've refilled two so far and they are both still working. One is on one of my Activas and the other is on a 406 that gets driven daily.

There are three different systems for the Activa. The very early one, the intermediate to cover the change period to the facelift and the Mk2. The dearest is the intermediate unit.

The same system is used on the HDi and the Peugeot 406.

If anybody has an old unit that is redundant, I would be happy to take it off your hands to look at sourcing or making replacement components. The same applies to the rams. If you can help, please PM me.

Handyman

[Sl4yer]

Hold on a minute there!

These supposedly sealed hydraulic clutch units can be refilled. All you need to do is take off the top of the reservoir, mount it so it is the highest point and administer fluid over a period of time. Any air bubbles will work their way north.

Makes sense. I was wondering why they would sell the piston separately, and why the manual lists the clutch fluid!

James

[CitroJim]

Makes sense to investigate whether refilling is a viable proposition.

Where there's a will, there's a way

[Brigsygtt]

The hydraulic clutch system can be refilled if necessary, seen it done the way handyman described with lasting success.