Recently the clutch on my '98 disco 1 died. Took a look through the access hole for the slave cylinder with a boroscope and saw the dreaded pivot ball poking through a fresh hole in the clutch fork.

I did a bit of research and found that Britrest seems to have the best solution to this weak spot. Rather than just welding a plate on the back like most 'heavy duty' aftermarket forks, they have put in a nylon bushing in place to eliminate the friction that causes failure, so I've ordered one to replace mine:

Super Duty Clutch Fork – Welcome to Britannica Restorations Ltd

As I understand this is a gearbox-out job so I have two questions for the community.

Firstly, what maintenances items should I tackle while I have the gearbox out? Previous owner has neglected maintenance and there are a few oil leaks. Rear main seal comes to mind, is there anything else that is advisable such as shifter linkage bushings or various seals and o-rings? The clutch itself seems to grip well so I'm not sure it's justified to replace it entirely but I'm willing to consider it if it's one of those "might as well" circumstances. Other things I've read on other threads are:


  • Spigot Bearing
  • Thrust Bearing
  • Vacuum Pump Gasket
  • O-rings for oil cooler pipes
  • Oil Thermostat o-ring
  • P/S feed hose to pump
  • Rocker Cover Gasket and Sealing Washers


Secondly, what is the most painless way to do this job? I've read other threads that say taking the engine out is an option but the consensus seems to be that dropping the gearbox is the easier way. I have a transmission jack, but it's a low profile one with a max height of 680mm. I've seen in some threads where people have made a custom bracket to bolt onto the gearbox and while I do have access to a welder and a drill press, I don't have much experience with fabrication.