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Just a follow up, Went through the hydraulics today again and still nothing. Decided to take out the transmission again and lay the whole clutch assembly out on the bench. As soon as I laid the pressure plate with the toothed springs down on the bench Bam!. The pressure plate rocked like it...

Hmm i will have to suss it out again the morning, however if it is leaking its all internal to the cylinders or leaking at some point i cant possibly see. I still havnt let get that it may also be air getting "locked" in their some where aswell. The only thing i havnt had serviced or replaced...

Sorry didnt pull the transmission apart, pulled it out to inspect the clutch and flywheel

The fluid level doesnt change and theres no external leaks. I have also had the slave cylinder serviced and doesnt leake through the boot. As for the fly wheel i discovered it does fit both ways without even touching the solid mass flywheel however i reinstalled it the same way the old one came...

It is actually a heavy dutch clutch in there. This is the second one i have had in it. I have actually been driving around with the current clutch for 2-3 months and then this all of a sudden this happened. I would agree that heavy duty clutches seem to cause more problems then anything else at...

Ok well after replacing the master cylinder, bench bled it then re-bled the clutch system and then cracked it another 6 times after all the air was out of the line.... the problem is still there. I took out the machined fork push rod i made up (15mm longer) and put the stock one back in and it...

The parts replaced were: throw out bearing, spigot bearing (input shaft brass bush) clutch plate, pressure plate and flywheel. I have just bled the system again and it came good but then slowly started to get harder to put into gear and pull out till i no longer could. I have just o/nighted a...

I feel pretty confident I have, even bled it a few times to double check. The fluid coming out has no bubbles or isn't air-rated. My brother is a mechanic and I have had him check everything as well.

I had someone reverse it up my drive way (which is steep and no more then 4m long) and have them hold in the clutch pedal as they roll back down. When they got to the bottom with their foot still on the pedal and in reverse, I stuck my head under and appeared to be that there was a very small...

Already have, seems to be full movement but i hadn stopped to watch it while its fully depressed and see if it bleeds back

Im thinking this is a clutch master cylinder problem. I have pulled apart the slave and inspected it, appears fine. re-bled the system with no worries. Machined a new fork push rod 15mm longer and installed it and only eliminated extra play. It seems to go into gear alot easier while running...

It doesnt appear to be the pivot point or clutch fork. I Just reassembled and reinstalled the transmission this morning and all looks fine. Im starting to run with the hydraulics. I have no leaks and I have already bled it with the same problem however I took up a little free play in the pedal...

Correction not unusual!

Hi, I own a 2006 D40 Diesel & manual 4x4. I current am having a clutch issue I cant seem to find on many forums. I was driving in 3rd gear doing around 40kph and went to shift into 4th and once out of 3rd it wouldnt go into any gear at all. I ended up rolling to a stop. I turned off the car...