2.0 hdi clutch advice

[Martinez]

Well, the bolts fit so not an issue, but thanks for the info I’ll remember that in future
Anyway, today’s the day for fitting new clutch, but there’s another bigger issue. The pressure plate sent to me is also wrong type. So back onto supplier who again apologised profusely and after quoting the part number on the clutch I was sent, he’s agreed to send me correct part 24hr delivery. Also has refunded full amount to me, so I get clutch for free and also keep the wrong one sent (it’s for a 1.6 he tells me). Had to pay my mate for few hours work and I won’t get time to do it now till later in week, but hopefully all the ducks are in a row now

[Martinez]

New clutch arrive, supplier said I could keep the other one (he says it’s for a 1.6) looks to be same as original fitted so hoping we’re good to go now. If not I’ll just buy one local. Let’s face it I’ve not paid anything for either clutch
Tomorrow looks like the big day trying to put gearbox back in. Got engine hoist ready to avoid heavy lifting. Wish me luck

[wurlycorner]

Good luck with it, hoping it all goes smoothly this time!
Astonishing that the supplier has been that good - given you two clutches for free!

[MattBLancs]

Good luck with the reassembly

[Martinez]

I’ve postponed the job until next Tuesday. Weather forecast says it’ll be hot as hell tomorrow.
Been there done that. Might go out for ride instead
Thanks for all the tips guys

[MattBLancs]

Ah, fair enough. Enjoy the sunshine ride instead

[Martinez]

Release arm

Today was the day to fit new clutch. It hasn’t gone well. Clutch fitted, thrust bearing, smear of grease etc. then after the struggle to get the box back on it doesn’t work. Pedal goes down n stays down. Seems the release lever is very stiff and no idea why. Have I buggered it up somehow ? No idea, it worked ok until now and I haven’t touched it !
Having said that, I did notice when box was on the floor I couldn’t move the lever by hand, I just thought it was a stiff return spring, but obviously there’s something not right. It’s a BE3 box on 2.0hdi lump. I’ve had to walk away today, I’ve had enough!

[MattBLancs]

If the image is of the type you've got then that looks like the Pull Type clutch. I recall (years ago!) fighting to get those "forks" engaged with the release bearing when changing the clutch on my old 306.

I'm not sure what happens if proceeding without them engaged (but pedal not returning would seem likely)


Good idea to walk away, coming back with a fresh head definitely a good way forward

[Martinez]

Hang on, I’m just taking my head back out of the oven
gonna have another look tomorrow. The thrust bearing just clips onto the forks I thought, or am I wrong ? It fitted fine. But why would the lever that the cable pulls go so stiff ?
I can only assume it’s the plastic bearings, but it worked fine with old clutch.
I even tried slacking off the bellhousing bolts, but no change. Push pedal down and pedal stays down.
And how’s the ‘automatic cable adjuster work’ ?

[MattBLancs]

Very worn bushes contributed to a heavy clutch on my 306, but nothing like the pedal staying down though.

On the 306 pull clutch, you have to angle the forks to tuck into the release bearing - as the gearbox is offered up to the block / clutch.

I didn't think HDi had pull clutches so I'm hoping not to be giving you a duff steer!

[Martinez]

Not like a 306 then I think. I’ll know in the next hour when I pull the box back off. Not looking forward to it

[RichardW]

It's easier the second time.... Did you replace the guide tube on the input shaft?

[Martinez]

After removing gearbox again, it still wasn’t obvious what the problem was. The shaft which operates the thrust bearing just wouldn’t budge without a lot of effort, so we ended up taking it out and cleaning it up. But as soon as you fitted it back into the lower plastic bush, it was tight again.
I was thinking I’ll just have to replace it with new part so knocked out the bottom bush and decided to clean up any corrosion around the hole it fits into. It was quite bad and I ended up scraping it out with a craft knife, but on refitting the bush the problem was solved. Corrosion on the aluminium bellhousing had pushed into the bush causing the shaft to stick.
After refitting the box and trying the clutch it was much lighter to operate than the old one.
So, here’s my conclusion, my clutch starting to slip may well have been due to it not fully engaging. When I removed the old clutch, it really didn’t look that worn. And the flywheel, thrust bearing and pressure plate all looked in good condition, as did the guide tube on input shaft.
One worth looking out for, and if replacing your clutch one worth dealing with before it’s a problem.
And another tip on how to get the pin out of the clutch lever, drill a hole in one of the fins on top of the gearbox and use a punch to knock it out.

[wurlycorner]

Great diagnosis, well done - and yes, that makes sense, your suggestion that the clutch may have not been fully engaging as a result.