Clutch Cover Brackets

The clutch actuator on the side of the gear box has a cover-plate to protect the mechanism from mud and stones.  There are two brackets at the front of this cover that frequently break due to vibration.  I have not seen any Daily 4x4s without these brackets broken!  Once broken they can make an annoying rattling sound while the engine is idling, so I wanted to find a solution. 

First, I simply re-welded the brackets to see how long they would last. Answer: less than 10,000 km!  Next I was tempted to simply change the brackets for ones made of thicker material, but I was concerned that this would potentially move the problem onto the next weakest component and then that would fail.  I therefore decided to fit anti-vibration bushes.  These bushes should provide the cover with the support it needs, but hopefully also allow for some vibration without overloading the brackets.

Here is a photo of the two broken brackets

And now with the anti-vibration bushes installed:-

       

 

 

 

And installed:-

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