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Thread: 200tdi clutch replacement advice

  1. #1
    Join Date
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    200tdi clutch replacement advice

    My son has been complaining of slipping when in 5th ... so needs to replace clutch.
    1992 200tdi 110
    I believe that the 130 clutch is a heavier duty unit and same size etc, so thought we would go that way, along with replacing throwout bearing .. anything else we should be considering?
    ALSO
    (1) have access to a two hoist vehicle hoist, so proposed to lower the gearbox on a jack, and lift the body (ie rest of the vehicle), rather than 'lower' the gearbox with an engine crane through the floor. (maybe should use a transmission jack?)
    Had a look/search here but there seems to be few users who have done this clutch change themselves, so advice please on strategies etc ...
    (2) anything we should be looking to do to gearbox (250k) while it is out?
    Thanks
    Last edited by rrturboD; 10th September 2012 at 10:10 AM. Reason: unclear text
    Michael T
    2011 L322 Range Rover 4.4 TDV8 Vogue
    Aussie '88 RR Tdi300 (+lpg), Auto (RIP ... now body removed after A pillar, chassis extension to 130 & fire tender tray.)

  2. #2
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    have a close look at the throw out fork if that the right name, the push rod from the slave cylinder wore a hole hole threw the lork/lever on mine

    re: lifting the body, isnt this a major on a 110? disco's and rangie are straight forward i thought

  3. #3
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    Quote Originally Posted by weeds View Post
    have a close look at the throw out fork if that the right name, the push rod from the slave cylinder wore a hole hole threw the lork/lever on mine

    re: lifting the body, isnt this a major on a 110? disco's and rangie are straight forward i thought
    Thanks for the fork advice, have adjusted the original message to clear up the 'lift body' text.
    Michael T
    2011 L322 Range Rover 4.4 TDV8 Vogue
    Aussie '88 RR Tdi300 (+lpg), Auto (RIP ... now body removed after A pillar, chassis extension to 130 & fire tender tray.)

  4. #4
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    Ive just done the job myself. Its a big job to do on your own. I did it with jacks and on my shed floor and took me about 7 days all up. (With rebuilding the transfer) Pulling the body off a 110 is a really big job! I think that removing the floor and lowering with a floor crane would be easier, but if you have a hoist, a gearbox jack would make it easy from the underside.
    You can remove the transfer case first which will be doable with two people lifting it down. Also, take off the transfer case lever as well as the gearstick, as the TC lever can get jammed up under the floor - it has to slide a long way back. If its a TD5 dont forget the wiring plug on the bellhousing (I did and ripped it off) If the transfer is fine and doesnt need work, just replace the seal between the GB and TC and seal the mating faces as well with silastic. There is really not much to do on the gearbox if its working OK as its a rebuild or do nothing kind of situation.

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