Hi Guys, I have a Pajero DiD 2003 with 193,000km on the clock, some of it heavy 4x4 kilos. About 6 months ago the gearbox started giving problems and the clutch plate, pressure plate and flywheel were replaced. The clutch master cylinder was also replaced, but it is still not right. When we travel for about 200km, the clutch starts slipping and it gets worse and worse. The clutch pedal comes right up and it doesn't release properly - it slips badly from 2nd to 4th gear. Replacing the master cylinder didn't help. This is not a problem when traveling short distances, only over longer distances. It is as if the clutch hydraulic system builds up more and more pressure as we travel further and then it starts to slip. Does anybody have any idea what can be the cause of this please?
It sounds like the problem is with the master cylinder. It needs to be adjusted ever so slightly. With continued use the pressure builds up and the pressure releases the clutch. Once it is stopped for a while, the pressure is gradually released and the system feels normal.
Have a look if the rod from the pedal is not adjustable. It must shorten. If not try and loosen off the master cylinder, slip 2 x flat washers in and tighten up (the master needs to move away from the pedal slightly). Try it and see if it sorts it out.