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Technical: 110 Station Wagon
Clutch Pedal Modification

The clutch pedal on Defenders is notoriously hard work but help comes, surprisingly, from Land Rover itself. There is available a collection of parts that replaces the existing overly heavy pedal return spring. I believe that these parts are standard fitment on the later Puma-engined models but they are a relatively easy retro-fit on TD5 and earlier versions.

The replacement parts consist of a spring, a U-shaped pedal bush and two small pivot bushes as shown below. The total cost for them was around 33, with the U-bush being by far the most expensive part.

In this parts diagram, the new parts are no's. 2, 3 and 4. The strangest thing is that the pedal and its' mounting are already designed to take these parts and have been since 1987, so I'v eno idea why Land Rover chose to fit a giant spring instead. Perhaps it was just cheaper.

Anyway, having purchased the parts, it's necessary to remove the existing spring. This is where I made my big mistake. The first thing to do should be to open the top of the pedal box in the engine bay and remove the nut securing the master cylinder push-rod to the pedal trunion. This allows much more free play in the pedal, which helps with removing the old and fitting the new spring. Some people that I've talked to have managed to fit the new parts without taking this step, but after an hour of struggling and cursing, I gave up and followed the instructions.

To access the pedal trunion, remove the six screws that secure the cover plate on the top of the pedal box. It's necessary to fully depress the pedal to undo the nut itself, so either rope in a helper or, as I did, use a length of wood jammed against the seat box. The pedal will now be free to be lifted up much higher than usual, which takes the strain off the existing spring.

With the old spring removed, the new U-bush and pivot bushes can be slotted into place. The U-bush fits in a slot on the rear edge of the pedal and the pivot bushs fit into holes in the pedal bracket on either side. This is quite fiddly, as the whole lot is tucked up in the footwell and obscured by the trim around the pedals, which is shown pulled aside above. The pivot bushes need to be helped home with long-nosed pliers or similar until they click into place.

With all of the bushes in place, the new spring can be offered into position from under the pedal and this is where it gets tricky. The two free ends can, by feel, be fitted into the pivot bushes quite easily. However, the 'U' end of the spring then needs to be compressed upwards to engage in the U-shaped pedal bush. With the pedal released as described above, lift it up as high as possible and then compress the end of the spring from beneath with pliers or a large screwdriver. If all goes well, it should snap home into the pedal bush, but this part can take some perseverance!

With the new spring in place, re-assemble the pedal trunion and the job is done. You will be rewarded with a clutch pedal that's much lighter to operate and, if you're like me, your knee will be very grateful.

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Page created: 25-Sep-2011