woody_2008 Posted January 6, 2012 Share Posted January 6, 2012 Hi, I wish my first post could be a good one but unfortunately not! The clutch in my 89' Defender needs replacing. The garage want lots of money to fix it about £500 I have seen on other forums and people have been saying to do them yourself, is this job possible, if I have a work space and an engine lift, can it be done!? Sam Quote Link to comment Share on other sites More sharing options...
western Posted January 6, 2012 Share Posted January 6, 2012 http://forums.lr4x4.com/index.php?showtopic=5010 http://forums.lr4x4.com/index.php?showtopic=6840 the 2 threads above should help, you can change the clutch by moving the gearbox as shown in the first thread, did my last clutch this way. Quote Link to comment Share on other sites More sharing options...
cluffy Posted January 6, 2012 Share Posted January 6, 2012 We did a clutch and decided the easiest way with the older engines is to just take the engine out and give it a good clean at the same time! Took 2 hours to get the engine out from when the truck arrived in the yard at 10am, it was out and running again by 3 with a quick lunch break! Real easy job too do, undoing the bell housing is probably hardest part Quote Link to comment Share on other sites More sharing options...
Mutz Posted January 6, 2012 Share Posted January 6, 2012 Engine out is easiest, thats what i found, especially if your doing it alone. Quote Link to comment Share on other sites More sharing options...
The Badger Posted January 6, 2012 Share Posted January 6, 2012 I just did mine, is a field, in the dark, with it snowing. Went the engine crane through the door route, but next time I will try the engine out option as access will be a million time easier and you don't need to man handle the gearbox / transfer box assembly. Quote Link to comment Share on other sites More sharing options...
discomikey Posted January 6, 2012 Share Posted January 6, 2012 i did mine one night, started at 7 with a mate, and drove it to college that night, via a macdonalds drive through at 1.30 am although i had done it before a couple of times. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted January 6, 2012 Share Posted January 6, 2012 Definately engine out is the best route Mo Quote Link to comment Share on other sites More sharing options...
discomikey Posted January 6, 2012 Share Posted January 6, 2012 not if youre on your own, its easier to line a box up with a engine than line an engine up with a box. Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted January 6, 2012 Share Posted January 6, 2012 Lining engine with box wasn't that hard .... once I remembered to turn the crank to get the splines lined up! I won't mention how long it took me to remember about lining up the splines! Quote Link to comment Share on other sites More sharing options...
cluffy Posted January 6, 2012 Share Posted January 6, 2012 Splitting the two and doing it all from underneath is easier alone, however I think it's always better to take engine out give it a good clean with sPray thinners and give everything a good look over. It's also a sight more comfortable while the engines suspended in the air Quote Link to comment Share on other sites More sharing options...
Disco-Ron Posted January 7, 2012 Share Posted January 7, 2012 if you decide to take the engine out route, if the splines won't line up straight away, remember not only to turn the engine via the pulley bolt, but also make sure the hand brake is on and its in gear, otherwise as i found out, the input shaft will just turn with the crank. . . A damn healthy wobble goes a long way too! Quote Link to comment Share on other sites More sharing options...
RustyNissanPrairie Posted January 7, 2012 Share Posted January 7, 2012 Just done mine, easy to take the engine out (2.5na), jack the front of the clutch bellhousing and make sure all the gearbox mountings are loose as you pull the engine makes it easy, also replace the rear crank seal at the same time if there is any sign of oil leakage from it. Took a few days but I wasnt rushing. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted January 7, 2012 Share Posted January 7, 2012 Gearbox back every time for me (and I've done loads ). Sam - what's your location? Les. Quote Link to comment Share on other sites More sharing options...
bushwhacker Posted January 8, 2012 Share Posted January 8, 2012 Hi Armed with good info from this forum I used the gear box back method, with use of an engine hoist through the doors. You will be in there to take out the g/box bolts out. Give it a test drive before you build it all back up. Only needed a second pair of hands/eyes to line the g/box back up. Quote Link to comment Share on other sites More sharing options...
woody_2008 Posted January 8, 2012 Author Share Posted January 8, 2012 Thanks for all the replies from what I can see the engine out option looks best. I am in Middleham in the Dales, only moved up here a few months ago by myself so I still haven't met enough people with Defenders! Sam Quote Link to comment Share on other sites More sharing options...
Disco-Ron Posted January 8, 2012 Share Posted January 8, 2012 Join a club Sam, thats the best advice you can get............ get to know other owners, and a few words of advice, if you go to the clubs monthly meet, make an effort to talk to people, don;t sit back and wait to be spoken too, cos unless you wear a land rover t shirt, no-one will know you're a land rover person!! we've had exactly this in our club, and we get moaned at for not welcoming people! Quote Link to comment Share on other sites More sharing options...
muddy Posted January 9, 2012 Share Posted January 9, 2012 Nice area youre in, i have a friend in kirby malzeard that i do some work for. I usually move the gearbox back as you dont have any fluids to buy/refill/bleed then,infact i should be swapping another clutch fork on weds and will be moving the box. Will. Quote Link to comment Share on other sites More sharing options...
Happyoldgit Posted January 9, 2012 Share Posted January 9, 2012 I've done it both ways and I would say if I'm working on my own then it's crane through the door and gearbox back. Quote Link to comment Share on other sites More sharing options...
Ex Member Posted January 10, 2012 Share Posted January 10, 2012 I've done it both ways and I would say if I'm working on my own then it's crane through the door and gearbox back. It does depend on the engine..... With the LT77 Defenders (2.5 NA, 2.5 TD, 200TDI) the bellhousing is very tight to the bulkhead. With the engine in its normal location accessing the nuts is very hard. I'm also not sure if there is enough space to move the gearbox backwards. 300TDI/R380 is a different story. Quote Link to comment Share on other sites More sharing options...
woody_2008 Posted January 10, 2012 Author Share Posted January 10, 2012 I have a Defender 200tdi engine fitted to a Discovery gearbox, will this be a problem doing the gearbox back method? I have a workspace and clutch kit ready for the weekend, but I'm worried now! Quote Link to comment Share on other sites More sharing options...
discomikey Posted January 10, 2012 Share Posted January 10, 2012 another tip for you if the engine is out and going back in, when turning the crank like said with it in gear and handbrake on. once they have lined up, if its still being a bugger, put it into neutral, and then turn the crank some more. and it helps to line up the crank in the lateral direction if that makes sense. i doubt it does but it works well! Quote Link to comment Share on other sites More sharing options...
Mutz Posted January 12, 2012 Share Posted January 12, 2012 Which ever way you choose to do it im sure it will be fine, problems will be small. And you have always got back up/advice on here. Quote Link to comment Share on other sites More sharing options...
woody_2008 Posted January 19, 2012 Author Share Posted January 19, 2012 Cheers for all your help. The car now has a new clutch kit, arm and flywheel re-surface. We took it to the garage in the end as we just weren't confident with what we were doing. I took it to Mr Clutch who did it for a really reasonable price. However I am now more worried than before. The car is shaking under acceleration (above say 45mph) and the transfer box rattles like anything in reverse. Could this be as a result of the garage changing the clutch? I'm starting to give up on this one. Any advice/help much appreciated. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted January 19, 2012 Share Posted January 19, 2012 In my opinion - Mr Clutch is probably the last place I would recommend to fit a clutch. In my opinion and experience, they are the worst of the worst. Les. Quote Link to comment Share on other sites More sharing options...
stuck Posted January 19, 2012 Share Posted January 19, 2012 Take the truck back to the "garage" immediately. Sounds like the clutch isn't aligned to me. Quote Link to comment Share on other sites More sharing options...
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