disco 1 clutch replacement - to do or not to do?

[POSBORNE]

I have a 200tdi, H reg standard disco 1, that's done about 220,000 miles. Thers's was no history with the vehicle when i bought it, and i haven`t changed the clutch, in the 3years i have owned it. Iys recently passed through an mot, but have just noticed that the clutch may be on its way out. the symptoms are that the revs can be be abit iratic sometimes amd not keeping a steady reading when at constant speed, othertimes it can be normal.

All i want to know is how long would it take to change a clucth? is it an engine out job, or can it be  done with the engine in situ? How much for a clutch? I was planning to get the garage to replace due to being a mechanic novice, but the garage are willing for me to get parts for them.

thanks

Paul

[Disco-Ron]

Paul, can you hear the revs changing, or indeed feel it, as the pick up for the rev counter is in the alternator...... could be something amiss with that, a lot easier to change an alternator rather than a clutch..!!

I would suggest that as a novice, it's a bit ofa big job, on a disco i would advise removing the engine to do it, as the gearbox is simply too heavy to do from underneath without proper garage equipment..... well, unless you want to be flattened by it..LOL!!!

[boss]

take the propshafts off, undo the bell housing,, take gear levers off, drop the gearbox and transfer box on to a trolly jack, roll them back and let the gearbox sit on the x-member.

change clutch, repeat in reverse order ;)

[JIMBOBLY]

as disco ron has said,take the engine out,you can do this with just three scaffold poles and a chain and block,basically make a tripod,and nearly all the work can be done from up top,you wont get wet and dirty,as much,and it is far safer too :)

[Range Rover Blues]

Get the H/D clutch kit for the TDi whilst you are at it.

[squaddie_fox]

got an engine hoist here...... :roll:

[meader]

trust me its a harder job doing it led on your back oh and it fecking hurts wen the box,s falls on you so take the engine out mate .or if your not in any rush take the tranny box off and then the gearbox

[stageonesimmo]

Got to agree - at work we never bother with the gearbox method (even with proper tansmission lifts etc) - just whip the front off and pull the engine - far easier and safer way to do it.

[marky]

I was a novice at mechanics, until I bought my disco!
I managed to change the clutch in mine just as Boss described above, and didn't find it too bad of a job. Heavy work, but not that difficult. I followed Les Hensons 'how to' on LR4x4 and borrowed a big jack! The hardest bit was the bolt on top of the bellhousing, hard enough to get out, but even harder to put back in!
Have a go, its very satisfying when you get it all back together and take it for a run.

[cooper956]

always done any 4x4 iv had by removeing the gearbox too much faff with engine fuel pipes, vac pipes, water pipes rad out inter cooler pipes. i just took props off, gearstick suround, gearbox xmember,speedo cable dropped the boxs useing a trolly jack with the box straped to it and slid it back out the way took 5 hours with brews and on my own nice to have help though just incase the box is a pig to get bk on.

[Disco-Ron]

One thing i've just remembered, the easiest way i found to get to the top bellhousing bolts was to lift the engine slightly, remove the engine mounts, then lower the engine lower than it normally sits..... that way you can get to the awkward bolts......

[squaddie_fox]

strip out the centre console remove gear levers and drill out the rubber gator, undo the props from transfer box, get a nice sling, round the gearbox and the transfer box, support the weight undo the mounting bolts, remove the cross member, drop the box a bit and jack the front of the engine a little. you can get to the top bolts with a few extensions etc, pull the box back from the engine dont need to pull it far, just enough to get your hands and a small ratchet remove the clutch.

 put new clutch in place, use a socket (cant remember what size off the top of my head, but a deep one around 14mm i think) to line it all up, bolt new one in, reverse process of the above.


not great at putting it into words but i hope you get the general idea. if you need a hand im around strtford upon avon and birmingham on leave for the next couple weeks.

[Range Rover Blues]

IIRC I can either get the top 2 bolts with a 14mm spanner I cut down and bent specially form above or using every extension in my toolbox from below, that way I end up under the back axle almost but I can do it.

[Les Henson]

I've never tried the engine out method, but that's usually because I'm doing the job on someone's drive/the road/pub car park  :lol:
The gearbox can't drop on you - the crossmember prevents that from happening, but the bellhousing can drop a rather scary distance. The available gap to work in to replace the clutch is only about 6-inches, so aligning the clutch is difficult and obviously very important. I use an old input shaft from a scrap gearbox, which is perfect.


Les.

[POSBORNE]

thanks for the advice guys, this is above & beyond my mechanical knowledge. At least i know the work involved & estimate the garage bill!

[squaddie_fox]

should only take a competent mechanic at most a couple of hours.

[Les Henson]

should only take a competent mechanic at most a couple of hours.

You've not done one have you? 2-hours to do a Disco clutch? - I don't think so.


Les.

[squaddie_fox]

i've done quite a few actually, and bar any problems (ok so at least one usually pops up) it wouldn't take long! [-X

[Xtremeteam]

i've done quite a few actually, and bar any problems (ok so at least one usually pops up) it wouldn't take long! [-X

the fastest time i have ever done a disco clutch in is 4 hours taking the box out which is the fastest way......



(served my time on landrovers at an independant specialist)

[Les Henson]

Yep, 4-5 hours is usually the time it takes.


Les.

[squaddie_fox]

yeah, leaking it down with rain, leisurely coffee breaks and a PITA to get back in it would take 4-5 hours! last one i did, ok it was at work not on a drive took 2 1/2 hours! 300 tdi! bit of practice and its easy!