The Clutch disc and Release Bearing for the TD4-Freelander, were replaced recently. The Pressure Plate was still in a good condition.Gears difficult to engage.Please advise.Tks.John.

A new clutch kit or clutch package has 3 major parts: a new clutch disc (the thin plate with the abrasive surface), a new or reconditioned clutch pressure plate, and a new clutch release bearing (aka, throw-out bearing). Approximately $200 for the package.
Some people have been known to change only the clutch disc (for about $30), and use their old pressure plate and throw-out bearing. Not recommended-same people have been known to have to go back sooner than later to then replace the pressure plate and release bearing. Do it all once, then you won't have to go back and re-do it.

Have you checked the hydraulic clutch operation? Before condemning the clutch disc for failure, make sure the hydraulic clutch cylinder causes the clutch fork or lever to have sufficient travel to engage the clutch when the pedal is depressed. Also check the clutch fluid reservoir for being full.

Well, it would shift easily with engine off, because the transmission input shaft is not turning. Engine running and clutch engaging good, the input shaft would again be stationary and allow smooth shifting.
What you have to determine is if the clutch disc or pressure plate is bad (a new clutch is needed), or if the pedal hydraulic system has a malfunction. When you push the pedal down, a rod from the top of pedal pushes into the clutch master cylinder bolted to the firewall under the hood. This cylinder has a reservoir filled with brake fluid. When the rod forces fluid from the clutch master down a steel line and into the clutch slave cylinder down on the transmission bell housing, the hydraulic pressure forces a plunger from the slave cylinder to extend and push the clutch fork lever a small amount, enough to force the clutch release bearing (aka throw-out bearing) against the pressure plate. This relieves pressure on the clutch disc and input shaft becomes stationary for easy shifting.

Fig. Fig. 1: Clutch release bearing - 1990 Colt hatchback and sedan w/ 1.6L engine, 1990 Colt Wagon w/1.8L engine, and 1990-93 Vista

Fig. Fig. 2: Clutch driven and drive discs - 1990-93 all models

Fig. Fig. 3: Clutch release bearing - 1990 Colt Wagon w/1.5L engine, 1991-92 Colt hatchback and sedan w/4-speed and 1993 Colt hatchback and sedan w/1.8L engine

1. Remove the transmission or transaxle as outlined.
2. Insert a pilot shaft or an old input shaft into the center of the clutch disc, pressure plate, and the pilot bearing in the crankshaft.
3. With the pilot tool supporting the clutch disc, loosen the pressure plate bolts gradually and in a crisscross pattern.
4. Remove the pressure plate and clutch disc.
5. Clean the transmission and clutch housing. Clean the flywheel surface with a non-oil based solvent. Wash your hands before installing or handling the clutch assembly parts. Hold the clutch disc by the center hub only.

Before assembly, slide the clutch disc up and down on the transmission input shaft to check for any binding. Remove any rough spots with crocus cloth and then lightly coat the shaft with Lubriplate.

1. To remove the throwout bearing assembly: Remove the return clip and take out the throwout bearing carrier and the bearing.
2. To replace the throwout arm use a / 16 in. punch, knock out the throwout shaft spring pin and remove the shaft, springs, and the center lever.
3. Do not immerse the throwout bearing in solvent; it is permanently lubricated. Blow and wipe it clean. Check the bearing for wear, deterioration, or burning. Replace the bearing if there is any question about its condition.
4. Check the shafts, lever, and springs for wear and defects. Replace them if necessary.
5. If you hadn't planned on replacing the clutch disc, examine it for the following before reusing it. Loose rivets. Burned facing. Oil or grease on the facing. Less than 0.3mm left between the rivet head and the top of the facing.
6. Check the pressure plate and replace it if any of the following conditions exist: Scored or excessively worn. Bent or distorted diaphragm spring. Loose rivets.
7. Insert the control lever into the clutch housing. Install the two return springs and the throwout shaft.
8. Lock the shift lever to the shaft with the spring pin.
9. Fill the shaft oil seal with multipurpose grease.
10. Install the throwout bearing carrier and the bearing. Install the return clip.
11. Grease the carrier groove and inner surface.
12. Lightly grease the clutch disc splines.

The clutch is installed with the larger boss facing the transmission.

1. Support the clutch disc and pressure plate with the pilot tool.
2. Turn the pressure plate so that its balance mark aligns with the notch in the flywheel.
3. Install the pressure plate-to-flywheel bolts head-tight. Using a torque wrench and, working in a crisscross pattern, tighten the bolts to 11-15 ft. lbs.
4. Install the transmission or transaxle as outlined.
5. Adjust the clutch as described in the following information.

You have a leaking master or slave hydraulic clutch cylinder. I recommend you replace both

Definitely a hydraulic issue. Iknow you said they were both changed, but its usually the master & slave assembly that go faulty on the Freelander. Both parts come filled with fluid and pre-bled and only require fitting, no bleeding. Check with garage to make sure they did not split / bleed them.

SECTION 308-00: Manual Transmission/Transaxle and Clutch - General Information 1998 Contour/Mystique Workshop Manual DESCRIPTION AND OPERATION Manual Transaxle and Clutch Manual Transaxle and Clutch - General Information This section covers general procedures for diagnosis and testing the clutch system. For additional information, refer to Section 308-01 . For specified clutch system service procedures. For additional information, refer to Section 308-02 . For a complete description of the manual transaxle. For additional information, refer to Section 308-03 .
The clutch system includes:

• Flywheel.
• Clutch disc.
• Clutch pressure plate.
• Clutch master cylinder.
• Clutch slave cylinder.
• Clutch release fork.
• Clutch release hub and bearing.

The clutch master cylinder transmits fluid pressure to the slave cylinder, which in turn moves the clutch release fork and the clutch release hub and bearing.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch disc has a hub which is splined to the input shaft. The clutch disc has friction material where it contacts the flywheel and the clutch pressure plate. Torsion springs on the clutch disc help absorb the engine torque pulses. The clutch pressure plate applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.
In the engaged position, the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft. When the clutch pedal is depressed, the clutch release hub and bearing pushes the diaphragm spring center toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transaxle and enabling the gears to be changed.
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Inspection and Verification - MTX-75
The following checks should be carried out before repairing or replacing the transaxle:
Poor gear shifting

1. Check the operation of the clutch: Lay a block of wood approx. 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop. If 1st or 2nd gear can be selected with no problem with the engine running and the parking brake applied, the clutch is OK. If the gear cannot be selected, repair the clutch.

1. Check the selector mechanism:
   • The free play in the gearshift lever must be no more than 15 mm.
     • If the gearshift lever free play is too great, check the gearshift cables and replace them if necessary.
   • If the gearshift lever free play is OK, adjust the gearshift linkage. For additional information, refer to Section 308-06 .

1. Check the transaxle fluid level and top up with Automatic Transmission Fluid ESD-M2C186-A if necessary.

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It seems like the clutch pressure plate has gone, not releasing the clutch plate once the pedal is operated.
The noise you hear, is it a screeching one or is it like the gears rubbing eachother.
If its a screeching noise thn its the release bearing and if its a heavier grinding noise thn its the gears.
Guess you will have to replace the clutch pressure plate, its highly recomended though to replace the pro-kit,i.e the clutch plate, pressure plate and the release bearing.
Good luck.

Clutch plate, pressure plate, throw-out bearing, and brake fluid.

If you put your car in 1'st gear, release the clutch pedal and nothing happens, absolutely the clutch is faulty.
Cheers

To reduce clutch disc/plate problems, avoid riding the clutch whilst driving, ie having ur foot on the clutch pedal when the engine is in operation, especially wqhen the vehicle is in motion. You see the clutch disc is sandwiched between the flywheel of the engine & the pressure plate. When the driver presses the clutch pedal, the sandwiching of the clutch plate is released, so therefore no drive is being transmitted from the engine to the road wheels. This gives an effect as if the vehicle is in neutral (engine can be revved, with no movement or propulsion of the vehicle). When the driver releases the clutch pedal, the clutch disc is now sandwiched tightly causing the drive to be transmitted to the road wheels which will now cause the vehicle to be propelled.

Clutch discs are only replaced when there are problemes with clutching in and changing gears. After constant pressing of the clutch, the asbestos material on the clutch disc after a period grinds down (clutch disc becomes thinner), which in turn will reduce friction characteristics when all the elements are sandwiched. This causes a slipping effect, preventing the drive from being transmitted to the road wheels efficiently. This causes other problems such as high fuel consumption, erratic engaging of gears, hard selecttion of gears, heavy vibration of the vehicle, stalling; just to name a few. In most cases an unusual smell of the clutch disc is observed.

Also just by resting ur foot on the clutch pedal while engine is running can be dmagaing too. You see the clutch release bearing rests on the pressure plate, so when the clutch pedal is pressed by the driver, there is a degree of friction being placed on the bearing because the pressure plate is always rotating with the engine. The clutch release bearing is stationery until the clutch pedal is pressed by the driver, which sends it into the moving pressure plate, so less pressing on the clutch pedal the less friction between the bearing and the pressure plate. Only operate/press/place foot on the clutch when necessary