RE: Clutch

[Richard Brake <richard.brake@domain.elided>]

Adding my two'pennerth, 'Orrible clutch problems I have had (mainly with
the Saloons but the components are very similar);

	1)	Clutch master spring breaking up causing insufficient
effective travel of the pedal.
		(this can get progressively worse)

	2)	Cross-shaft bush's worn. (Also causing insufficient
effective movement of the bearing carrier)

	3)	Worn cross-shaft. (Usually when the above bushes are
shot).

	4) 	Cross-pin snapped (this is horrible it can be very
difficult to remove the remains).

Any time I have the gearbox out I always check the cross shaft-bush for
play and replace the bush's with the after-market wider ones (these are
nearly twice the width) although I suppose you could put two bush's in
each side!

Also when fitting the pin check that it is neither loose nor tightens to
early. You can get oversize pins for the 2000//2.5 I believe these are
the same as Stag although the cross shaft is different (something about
stag's and Sprints have the starter motor on the wrong side). The hole
can be cleaned "CAREFULLY" with an 11/32 "1 in 48" Imperial taper
reamer. I actually got my friendly 2000 specialist to do this for me.
The pins are only 5th wider but it saves the cost of a new cross-shaft.

Also check the bearing carrier, the pivot pin bush's in the carrier and
the spigot bush. The number of times people who have had clutch problems
and it's nothing to do with the three bits they change (Pressure plate,
Friction plate and Bearing). 

At Stonleigh I saw a TR3 gearbox which was very similar to the
Stag/2000. It had grease nipples on the cross-shaft bush's. Yet another
good idea removed  in the name of cost engineering and low servicing
costs. Maybe I'll drill and tap my gearbox's from now on and fit the
nipples.

Richard Brake