Verified answer

Manual Disco's have a tendency to wear out the clutch release arm which causes a lot of free play in the clutch.

They can be pigs to bleed, but there are two other possibilities. Firstly, a faulty slave cylinder. Easy enough job.

Secondly a problem with the clutch operating arm. This is quite flimsy, and the pushrod from the slave to the operating arm can push its way right through the arm, leaving you with no clutch. It happens quite a lot, and reinforced components are available.

It happened to me 5 or 6 years ago, and sadly I'd already bought a new master and slave before I worked out what was happening.

Yours could be on it's way, so if you get the slave off this weekend try and see whats happening in the bell housing before you put it together again!

Good luck!

Are you sure you have bled the system correctly?

Press the pedal down open bleed screw, close bleed screw release clutch pedal. Requires 2 man operation with hose connected to nipple immersed in fluid in a container. Man in cab shouts down, release bleed nipple, having released nipple and then closed it again shout up.

continue until all bubbles are clear in container.

the clutch pressure plate is not clearing properly the springs will be worn out .Change the clutch im sure that will cure it.

There is still air in the system.You may need to change the slave cylinder washer