selectcase Posted April 2, 2009 Share Posted April 2, 2009 I have never had any issues with the clutch on my 98 300tdi disco until tonight - on the way home the gears grunched once or twice and i thought the clutch might be on the way out - then i depressed the clutch pedal and it stayed down(just a well i was on a country road at the time and not in town - i pulled over thinking either the master or slave cylinder however once the rac had recovered my car and got it home i notice the clutch pedal only goes 2 thirds of the way down then stops dead/solid I am thinking this might be a worn/broken clutch fork as there is no fluid loss and no previous problems - if this is the case I will replace it as I have done other clutches etc on my series lr - however any tips on this job - is it easier to remove the engine or the gearbox? I have an engine crane but no pit or ramp any advice gratefully recieved cheers will Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 2, 2009 Share Posted April 2, 2009 I bet £10,000,000 it's the clutch fork. Les. Quote Link to comment Share on other sites More sharing options...
hattymender Posted April 2, 2009 Share Posted April 2, 2009 When mine went the pedal just went 'solid'. The fork was hard up against the back of the bell housing with the pushrod fully extended, hence 'solid'. Is your slave leaking into the bellhousing? Re: best way. Unless things have changed since LT77 boxes it's easier to move box back than lift engine. Same as series, disconnect props, tunnel and gear levers. Then support box and back of engine (you've got a hoist? I've done it with jacks) remove bell housing bolts and hope it parts. Mine didn't (stuck together for 20 years?) and it needed an 'uncomfortable' amount of levering to part them. You should have enough room before it hits mid body cross member (the arched one on a 110, 90s don't have one?). A bit more space can be made by removing handbrake drum but you shouldn't need it. Quote Link to comment Share on other sites More sharing options...
hattymender Posted April 2, 2009 Share Posted April 2, 2009 Disco? Sorry, I was in 110 mode Still should be easier to move box than engine though? Quote Link to comment Share on other sites More sharing options...
selectcase Posted April 2, 2009 Author Share Posted April 2, 2009 Cheers for advice - just had another cursory look and the pedal only goes arond 1/2 way down so yes i think its the clutch fork. I had a look at the technical archive (great stuff) wehre Les details the gearbox removal so i will have a ponder which way to go - its due a cambelt change so I may as well do that at the same time and put a clutch in while its split. Quote Link to comment Share on other sites More sharing options...
inchman Posted April 2, 2009 Share Posted April 2, 2009 this happened to me and the center had melted trough on the release bearing cheers Gary Quote Link to comment Share on other sites More sharing options...
Godlykepower Posted April 4, 2009 Share Posted April 4, 2009 I recently fitted a heavy duty clutch (well my garage did!) and they said best is for g/box to come out. They also made me up a strengthened heavy duty fork at the same time. Quote Link to comment Share on other sites More sharing options...
pedro Posted April 5, 2009 Share Posted April 5, 2009 Clutch fork for sure, happened to my bro on way back from Morocco, car still drives if start car in gear and turn key as limp home/to nearest garage. Suggest replace clutch plates and HD kit, IMHO. Quote Link to comment Share on other sites More sharing options...
freeagent Posted April 5, 2009 Share Posted April 5, 2009 Les Henson (on this forum) does a nice line in strengthened clutch forks from time to time (a lot better that the carp Britpart one) might be worth a PM to see if he has any knocking about.... Quote Link to comment Share on other sites More sharing options...
western Posted April 5, 2009 Share Posted April 5, 2009 got one of Les H's in my 110, worth the outlay, but not sure if he has any left. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 5, 2009 Share Posted April 5, 2009 I've got three here at present. Les. Quote Link to comment Share on other sites More sharing options...
selectcase Posted April 6, 2009 Author Share Posted April 6, 2009 Thanks for the offer but I picked one up at Tor on Friday - Nearly got the engine out - I am going the engine route as there are a few other jobs i need to do with the engine out. I just have to get the bolts off the bellhousing today - oh joy oh rapture - not. Quote Link to comment Share on other sites More sharing options...
steve_d Posted April 6, 2009 Share Posted April 6, 2009 Thanks for the offer but I picked one up at Tor on Friday - Nearly got the engine out - I am going the engine route as there are a few other jobs i need to do with the engine out. I just have to get the bolts off the bellhousing today - oh joy oh rapture - not. The fun ones are over the top. Lift the engine and remove the engine mounts. Lower the engine as far as pos and the top bolts become a whole lot easier. Leave the lower ones in place until after you have lifted the engine again and supported the front of the gearbox. Steve Quote Link to comment Share on other sites More sharing options...
rusty_wingnut Posted April 6, 2009 Share Posted April 6, 2009 I'm in that issue 3 times. Quote Link to comment Share on other sites More sharing options...
markt Posted April 6, 2009 Share Posted April 6, 2009 I've got three here at present.Les. Hi Les, how much are they ? & how much for p&p cheers, Mark Quote Link to comment Share on other sites More sharing options...
selectcase Posted April 6, 2009 Author Share Posted April 6, 2009 The fun ones are over the top.Lift the engine and remove the engine mounts. Lower the engine as far as pos and the top bolts become a whole lot easier. Leave the lower ones in place until after you have lifted the engine again and supported the front of the gearbox. Steve Well today was a difficult and demorilisig day, I have done loads of engine changes, gearbox jobs on various landrovers i have owned over the years but not a 300tdi disco before. I removed the mounts and lowered the engine as far a possible until the timing cover just touched the power steering box and those bolts are still damm difficult - I got all of them apart from the top central one which i will attempt tomorrow - i can reach it with extension bars but of course its in line with the gearstick - i have even removed the central console etc to improve access but that top one looks a Bu**er to get to and undo - the others were really tight and needed a 1/2 drive torque wrench to get them to move any advice on the last one greatly appriciated. Quote Link to comment Share on other sites More sharing options...
titan Posted April 6, 2009 Share Posted April 6, 2009 just did a clutch change today on my 300 tdi disco thank the gods the very top nut on the bell housing wasnt present the rest of the topish one we reached with a selection of extentions and flex nuckels one person under putting the socket on the other loserning the nut through the centre consale in side Quote Link to comment Share on other sites More sharing options...
selectcase Posted April 7, 2009 Author Share Posted April 7, 2009 Managed to get the last bolt off this morning - used a new surface drive socket 1/2 inch drive to make sure it didnt slip - a range of extension bars and reducer down to 3/8 drive and 1 uj half way along to allow it to angle up in to the centre console/gearstick hole - 45 minutes to get this combination sorted but thank got it worked - that nut is not going back on Thanks to Les for his excellent article on removing the centre console for access - couldnt have done it wthout that Quote Link to comment Share on other sites More sharing options...
landkeeper Posted April 7, 2009 Share Posted April 7, 2009 iv'e done this job a few times now and it's easier to drop the gearbox , the way i do it is remove both props and all the gubbins from around the gearstick ,disconnect the wiring from the box and then remove the gearbox mounts/xmember then let all the weight of the gearbox hang on the back of the engine. that should twist the engine on it's mounts so that you can easily get to all the bellhousing bolts oh leave a bolt or two at the bottom of the bellhousing till your ready to take it out Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 7, 2009 Share Posted April 7, 2009 Hi Les, how much are they ? & how much for p&p Postage is free (paid for out of my dole cheque ) £15 each - paid into the website gin fund. Les. Quote Link to comment Share on other sites More sharing options...
selectcase Posted April 7, 2009 Author Share Posted April 7, 2009 I bet £10,000,000 it's the clutch fork.Les. Glad I didnt bet you Les or it would be £5k per week for the rest of my life Quote Link to comment Share on other sites More sharing options...
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