Clutch Issues and Diagnosis

[Dunco]

Hi Everyone,

I am looking for some help diagnosing and, if required, replacing my clutch.

Early last year the local LR mechanic had the Discovery’s (2000 V8) Air Conditioning regassed and noted that the clutch was particularly worn. Upon asking if that was usual for a vehicle with less than 60 000kms he thought it wasn’t and to keep an eye on it. The vehicle has a rear main oil seal leak which I am wondering may have led to a shortened clutch life.

Since I was told the clutch was worn I have bled the clutch and noticed that the clutch pedal did not return of its own accord as the manual suggested it would. Since there was no leak of the clutch/brake fluid I concluded that the slave cylinder was ok and that the clutch master cylinder was internally binding. I have just replaced the clutch master cylinder and there has been no change in the engagment point.

This leads me to believe the clutch is in fact worn. Can anyone support my diagnosis or suggest alternative checks to be performed.

Presuming it is the clutch the second part of the question is do I need the special tools for locating the clutch (LRT-12-001) and gearbox support (LRT-99-007) to aid lowering the gear box out of the vehicle? I suspect the clutch locating tool could be machined if the size of the input shaft was known. Does anyone know this measurement off hand? On the condition of the flywheel does it only require resurfacing if it is seriously scored?

I was planning on an Exedy replacement clutch, anyone have any experience with these. They don’t offer a heavy duty clutch although I was only considering one due to this one appearing to wear prematurely I don’t do any substantial towing that would require it.

Thanks in advance,
Duncan.

2000 Disco V8, Sequential Gas Injection
1950 S1

[BigJon]

Clutch aligning tool - make your own. I used an old steering shaft built up with electrical tape. Worked perfectly.

Pulling the transfer case and transmission out on the floor at home is a big job. Doable, but I wouldn't recommend it.

I didn't get my flywheel machined (emery cloth did the job) but I didn't replace my clutch either (I was replacing my engine).

[Blknight.aus]

if your going to drop the box that can be achieved with some mates some good rope, a trolly jack and some bolts cut down into guide rods.

not something to be undertaken lightly

theres no need for the special aligning tool

make one, borrow one or just temp it up...

if youve got a good eye you can get the new clutch in by eye.

good luck

[Dunco]

Thanks for the details. I will seek a few quotes :o to fit especially in light of the clutch appearing to wear prematurely I would hate to have the box out and find other issues that I couldn't deal with. I also have an idling issue on gas so I may end up taking it to Bruce Davis for the clutch at the same time.

Much appreciated,
Duncan.

2000 Disco V8, Sequential Gas Injection
1950 S1

[russotouristo]

Dunco, could you please point to the clutch you used? What was the engine and gear box?
Did you replace just the disc, or the whole assembly? (with a spring and may be a bearing)
By the way, did you take any pictures?
Thank you