D3 Tdv6 Clutch job

[justinc]

Hmmm, this has been an interesting job. I had an EAS leak to find, fuel pump and timing belts to check/ replace so I decided to remove the body to do the clutch so I could get to the other bits (Especially that darn fuel pump belt).
It then transpires that 'Oh, the belts were actually done last year' when I rang the service centre up north for a history, so 'bother' thought I, oh well body is off in 3 hours so no sweat, we'll do the clutch job and flywheel etc etc and it all went without a hitch, EXCEPT... this vehicle must've been in some salty conditions, because all of the exhaust studs and nuts and turbo support bracket studs and nuts were rusted. Solid. They were staying put.

there was also some wiring issues as at some point the vehicle had I guess been involved in some sort of accident, as the compressor loom where it is plugged in behind the LH inner guard had been joined together and hardwired, instead of multiplugged so a cutting I had to go, and rejoin later, but by far the worst example was the Main body earth strap stud and nut under the RHF guard liner it was corroded and actually broke out of the guard when I tried to undo it, this is a critical earthing point and will cause all sorts of horror if it fails or looses its earthing capabilities during use. We made a new strap, then bolted it securely through the actual guard in another place.

Removing the trans, fitting new flywheel, clutch slave and reassembling trans, Realigning and refitting the body so far has taken a further 6 hours, so my estimate of around 10 isn't far off.

I have now got a copy of LR's destructions on trans removal, without body removed, and it doesn't look too horrific at all except that without being able to remove those brackets and exhaust crossover pipe etc it would've been a nightmare

All in all an illuminating experience into D3 design, and I am impressed at the ease of body removal and overall engineering it has taken to build these vehicles

JC

[400HPONGAS]

Jeez,Justinc,you get the good ones ! As a matter of interest , how many K's has that clutch done ,and what was the condition of he Flywheel,the pressure plate(s) and clutch plate ?Never even seen a manual , let alone a manual with air suspension ,got some coilers with auto's tho.!

[justinc]

Jeez,Justinc,you get the good ones ! As a matter of interest , how many K's has that clutch done ,and what was the condition of he Flywheel,the pressure plate(s) and clutch plate ?Never even seen a manual , let alone a manual with air suspension ,got some coilers with auto's tho.!

My impression is that the clutch isn't up to the task, this will be confirmed by a 'D3 clutch failure' google search of UK sites It is about the same OD as a Tdi clutch, but obviously much higher clamping pressures. Dual mass flywheel was trashed and a nice turquise colour, it had been towing for quite a bit of its life, and was driven around with a slipping clutch for a week before I got to it Bellhousing smelt like an ashtray

the vehicle has travelled 180K, this is its first clutch as far as I can make out.

It'll need another if they don't use low range to get up the boat ramp or maneuvre the horse float around in future.


JC

[BigJon]

D3 with a manual trans and air suspension? Special order vehicle? I didn't think that spec was available in Australia.

[101RRS]

So JC - is the body designed for easy removal with quick releases and easy to get at fixings (eg wiring looms, steering, brake pipes, A/C pipes, Heater pipes etc) or is it really the same as any other vehicle with a separate chassis?

Garry

[Tote]

D3 with a manual trans and air suspension? Special order vehicle? I didn't think that spec was available in Australia.

Yep, It was available but only as an "S" I looked at ordering one when I bought my 2008 D3 but the cost of a manual S with air suspension and 7 seats was more than an SE with an auto. ( and you missed out on bi xenons, puddle lights and some other bits and pieces that were only available on the SE.)

Regards,
Tote

[justinc]

Damn.

Connected battery etc and no crank, hazards on and no fob comms. looks like it has lost its 'memory' between fob and BCU.

only 5 days disconnected (Over weekend) but still


JC

[justinc]

So JC - is the body designed for easy removal with quick releases and easy to get at fixings (eg wiring looms, steering, brake pipes, A/C pipes, Heater pipes etc) or is it really the same as any other vehicle with a separate chassis?

Garry

Yes it is actually very easy, it is designed to be removed for repairs. the only pain is de gas and re gas A/C
Steering angle sensor will usually require recalibrating etc afterward too, but overall it has been designed with R&R in mind


jc

[scarry]

overall it has been designed with R&R in mind


jc

That is a major surprise

[justinc]

That is a major surprise

I didn't mean Rest and Recuperation...

JC