Thread: clutch replacement at home

Originally Posted by weeds

hey guys

a mate of mine is about to replace the clutch on his 300tdi at home

any tips prior to starting that might make the job a bit easier, at this stage he will remove the transmission/t-case, he has jack stands, trolley jacks etc

Q - clutch kit? which is best

Q - clutch aligning tool

anything else he should look at while the box is out

Can't comment on what clutch kit, as I haven't done that model. Clutch aligning tool - simplest is to make one - note they can be made of wood, all you need is a wood lathe, measure the diameter of the inside of the splines in the plate and the diameter of the pilot bush.

Expect to replace the pilot bush and have a very good look at the throwout fork - either replace or reinforce it or both. Check for oil leaks from gearbox and engine.

John

he has access to a machine shop so i'm sure he could knock one up

I made an alignment tool from a long reach socket that fitted the flywheel bush snugly and then wrapped insulation tape around it where the clutch needed to be until it was snug too. Worked a treat, cost next to nothing and took all of 2 minutes to produce.

I have a couple of input shafts, hes welcome to borrow one of mine.

A couple of dowel bolts to help with sliding it out and back will be a godsend.

I usually cheat abit and find a 3/8th socket that fits into the spigot, put a 1/2 inch socket in the friction plat and then slide a 3/8th extention bar through the 1/2inch socket and fit it into the 3/8th socket in the spigot.

Im also a big fan of a padded block of wood across the wings to help support the back of the engine at the exact position you want it in with a safety rope to the top of the bell housing.

also IMHO 3 blokes is the best number of people to mandraulic the box out, one to stabalise the bell housing, one to stabalise the tcase side and one to co-ordinate/drive the jack. (not such a big deal if you have a proper trans jack.


when it comes time to assemble put a 12 inch long section of 3/4 inch hose over the clutch pushrod and poke it through the clutch slave hole.

cant wait for the tutorial!

Yeah! Can we watch?

i think a step by step picture session is in order that would be helpful to many !!!
good luck

Originally Posted by lardy

i think a step by step picture session is in order that would be helpful to many !!!
good luck

I'll see what I come up with...