Thread: Clutch Replacement???

I'm replacing my clutch this weekend too.
Good time to replace the rear main seal (remember dont touch the seal and dont oil it!)
Also the spigot bush.
Also get the flywheel ground to remove any hot spots.
I'll be removing the gearbox, as it is being replaced anyway - after a catastrophic failure of the last one!
Also, you'll need a clutch alignment tool to locate the friction plate.
Oh, and lastly, replace the actuator fork as these are prone to failure...

hey james i see you about to hav some fun changing the clutch well my mate got me a heavy duty clutch from some place in queensland and it seems to be holding up very good.. he done the work for me and he just moved the motor rather than take the gearbox out but mind you he has done enough to do it with his eyes closed he installed the clutch via moving the motor and also took the injector pump off and done some work on it for me and got it all back together in around 4 hours and it was ready to test run

hav no idea about disco wat so ever so i am just asuming taking the gearbox out and sitting it on a stand under the hoyst would be the best way because u wont hav to take radiator cowlings off or all the auxillary lines on the engine

Bear in mind that the Gear Box and Tranfer case is VERY HEAVY,
I removed mine via the engine crane through the passenger door after I removed the gear lever console onto of the transmission tunnel.

From reading what you guys have to say sounds like taking the gearbox out might be the better option...

As for parts i have:

1. Heavy Duty Clutch
2. Machined Fly Wheel
3. Spigot Bush
4. Rear Main Seal
5. Heavy Duty Clutch Fork... as this is what caused the failure in the first place!

I will look into getting an alignment tool... and some courage to tackle this job!

"in my 98 D1 300tdi discovery "
I believe in a disco it will be generally easier to pull the engine than drop the gear box if by "hoist" you mean engine lifting hoist. The access hole after you remove all the internal disco trimmings is much tighter than pulling the covers in a fender. Also relatively time consuming.

Also means you are working standing up rather than rolling around on your back.

I would make my mind up on what else may need doing. If its time to flush the radiator and intercooler I would pull them then the engine, but if the Gbox/Tcase needed seals / bearings or linkage work or the prop shafts needed unis I would consider pulling the drivetrain.

Have fun!!!
S

Roverrescue you have raised two key points! one being rolling around on my back on the hard cold concrete... i think i would much rather stand up... so in a swift 180 i am now going to take the motor out I have very little idea on what i am doing... to do this so i will be having a couple of mates dropping in to give me a hand here and there and some pointers... main thing i hope to get from this is knowledge for next time!

Originally Posted by Grover-98

Roverrescue you have raised two key points! one being rolling around on my back on the hard cold concrete... i think i would much rather stand up... so in a swift 180 i am now going to take the motor out I have very little idea on what i am doing... to do this so i will be having a couple of mates dropping in to give me a hand here and there and some pointers... main thing i hope to get from this is knowledge for next time!

You'll be able to stand up once you've undone all the bolts holding the bell housing on, engine mounts, exhaust, etc. Find a garage floor creeper or nick a bit of soft carpet for the underneath jobs and you'll be fine. I have a sheet of 8mm plywood that keeps me out of the cold dirt. Just don't let everyone else walk their dirty boots on it before you lie on it.
Taking out the motor for the clutch is best because nothing beats being able to eyeball the motor back end in broad daylight.

Hey James,
Give carters at east maitland a call regarding a clutch aligning tool, will set you back about 8-10 bucks most likely. Also what tools do you have there? i might bring my floor creaper and some tools if you dont have alot, should be able to spare a little time either day, maybe even bring some extra helpers...

Mick.