Clutch Master Cylinder and Finding Engine Oil leak

[bf900]

Folks,

I jumped into my truck one raining afternoon after a long days work to find my clutch pedal with very little pressure. I suspected the Clutch Master Cylinder because it had been leaking for ahhhh couple years. But no...it was the slave that blew it's gasket and spewed fluid all over the bell housing. After I removed the slave and pretty much emptied the system of fluid....I was faced with the decision to tackle the master...I was feeling brave that day and decided to take it on. Needless to say, it was a pig to remove because the Brake Master Cylinder and Servo had to be pulled away from the bulkhead and lines moved around. However, a couple hours later I was victorious and had the clutch pedal box on the bench. I ordered all the parts and started looking at my trusted 300tdi with 385k. There had also been a slight wetness around the valve cover but more concerning, underneath the intake manifold/exhaust manifold. I inspected a bit further and saw that there was a little bit of wetness around the valve cover...so I removed it and cleaned all around. It's possible that the wetness on the side of the engine is originating from the valve cover but what if it's not. Where else could it be coming from? Given that all my tools are out, the hood is off and I'm feeling brave should I inspect the intake/exhaust gasket? Is it possible the oil could be coming from the intake manifold?

I removed the main hose that feeds the intake manifold and inspected for oil but it looked really clean.

Looking for some thoughts/ experience if oil could be coming from the intake/exhaust manifold gasket...or should I just button everything up and see if a new valve cover gasket "fixed" the slight leak. Is pulling the exhaust manifold away from the block risky? The manual makes it seem straight forward but thats if all the bolts cooperate.

Thanks

Bert

[Dave_F]

When you say "wetness"...is it like antifreeze/coolant?

It could be your P Gasket. If you look at the engine block behind the Alternator (standing at the side fender) and you see "wetness" chances are it's the gasket gone. These are a known problem.

If it is, make sure you get the proper "genuine" metal type, and also pick up a new water pump gasket at the same time.

Not that hard to do, just fiddly.

[red90]

You need to clean it really well, then drive and see where it is coming from. You can get oil from the intake manifold or could be valve cover or head gasket.

Manifold gaskets and head gaskets are very easy to change. Easier than the clutch cylinders..... Timing cover leaks are the real pain.

[ANDYD]

I agree, give it a good hot power wash, get it nice and clean. Put on a new valve cover gasket and monitor to see if the leak returns.

Most likely coming from the valve cover gasket in that location. I have a spare valve cover gasket you can have if you need one.

cheers,
Andy

[bf900]

Thanks guy's. I decided to remove the intake manifold only....easy 2 bolts and two nuts. It allowed me to have a good look at the whole left side of the block. It's wet to the touch...not dripping wet but damp. Doesn't look /feel like coolant. I'll give it a good clean and replace the valve gasket / then re-examine.

IF the oil is coming from the intake manifold...is this normal or indication of another issue?

Andy: thanks for the valve cover gasket but all the parts arrived yesterday.

PS: I also looked at the where the P gasket sits but looks dry.

B

[red90]

The gasket is a single gasket for both exhaust and intake manifolds. You need to pull both to change the gasket.

http://www.allbrit.de/DataImages/MGROVER/ahbnha1a.gif

Thanks guy's. I decided to remove the intake manifold only....easy 2 bolts and two nuts. It allowed me to have a good look at the whole left side of the block. It's wet to the touch...not dripping wet but damp. Doesn't look /feel like coolant. I'll give it a good clean and replace the valve gasket / then re-examine.

IF the oil is coming from the intake manifold...is this normal or indication of another issue?

Andy: thanks for the valve cover gasket but all the parts arrived yesterday.

PS: I also looked at the where the P gasket sits but looks dry.

B

[bf900]

Thanks King Kong. I was aware of that...I was referring to the valve cover gasket in my previous message.

I took couple more pictures. One shows the amount of oil just inside the manifold intake when I pulled it off.

The second picture shows the amount of oil/wetness on the block (where the manifold attaches to the engine) - I'm leaning towards the theory the oil was coming down from the valve cover (it's been clean already).

Could there be some sort of oil blow back from the valves into the intake manifold. I can kinda see them in there and a couple of them looked gummed up? carbon?

I'll be re-installing the clutch master cylinder tomorrow...wish me luck.

B

[red90]

Oil is normal in the intake. It comes from the crankcase ventilation system.

The manifold could have been leaking from that photo. Might want to use a bit of sealant on it before putting back together.

[bf900]

So I installed the slave and master clutch cylinder....bleed the system (two person) - following the manual....but I still don't have much clutch pedal pressure....also...the pedal stays near the floor when I press it...as if the pedal spring holds it down but I have checked it several times and pretty sure the spring is installed correctly....why no pressure ?

[ANDYD]

Hi Bert,

If the pedal if down and feels floppy it could be your clutch fork gone thru the pivot ball, very common if you have the old style fork installed. Happened to me last year.
http://www.roverlanders.bc.ca/roverforu ... f=5&t=7078

I hope not as it will need clutch out to repair .....

-Andy

[bf900]

Can't b that. ...just had new clutch put in at Aarts couple months ago. Thanks tho

[red90]

They can be difficult to bleed. The way the slave sits can trap air. I've had good luck bleeding with the slave out of the bellhousing and hanging down. Just open the bleed nipple and the air gets out by gravity. Sometimes if the air is trapped up high, it will work its way out overnight.

[bf900]

Thanks. I searched a few forums last night and one thing that was mentioned was to make sure the bleed nipple it in the top position...I happened to install it with the bleed nipple in the bottom position (closest to the ground).

I'll switch that around and keep bleeding it.

I'll also double check that the pivot arm is still connected to the lever inside the bell housing (I was careful when I removed the slave but who knows...).

B

[bf900]

I removed the slave...reverse bled it while it hang...then re-installed it and with the bleed nipple in the top position and pumped the clutch....voila...pressure and beautifully smooth gear changes. Thanks everyone for the feedback and morale support.

B

[ANDYD]

Good to hear you have it resolved. Hopefully you have years of problem free clutch usage now!

[bf900]

Is there suppose to be a gasket or "spacer" between the slave cylinder and the gearbox? (R380)

I noticed a slight "drip" develop under the slave, but everything is tight. I've seen some schematics that show a "spacer" and others nothing at all.

Rovers North show a spacer but its 24 bucks...ouch.

PS: The old slave had a thin rubber gasket.

Thanks

B