Problem after problem, now clutch or gearbox? Now fixed!

[marky]

In the last 2 months:

Cracked head - new head, still overheated and lost coolant,
Core plug - fixed, still overheated,
New stat and pump, still over heated,
New rad - temp fine but no hot air, so bypassed matrix!! All fine for about a week until....
Starter motor packed up - it was getting lazy!
And then the clutch (i hope) started slipping on longer runs, untill swmbo picked the kids up from school, started the engine and put in gear and there was no drive at all.
It's took me a week to get the gearbox off (seized mount and bellhousing bolts, as well as wife, kids and work) finally moved the gearbox back today and the clutch plate looks ok- theres still grooves in the friction material, but I've replaced it anyway. I'm really struggling to get the gearbox back on, but am I wasting my time? Could this really be a gearbox issue?
 :D :D

[Sharpshooter]

Was the clutch fork ok? This is a common problem on the disco. Either punched a hole where the pivot is, or split and not releasing the release bearing. Also, try putting the difflock in and turning the drive flanges to get the spline in.

[marky]

I didn't take the fork off, but it looked/felt ok, bearing was fine but replaced that too.
 I can't even lift the bell end - sorry, housing up anywhere near high enough, its just too damn heavy- or my muscles aren't big enough!

[Ja1983]

....trolley jack.

[marky]

But the trolley jack is under the handbrake drum

[Dr Neil]

To make life easier have you got a ratchet strap that you can loop over the chassis and attatch to the out riggers,and under the bellhousing.That way not only can you ratchet the front end up but should the worst happen and it slips off the trolley jack it won't land on you or the floor.If not borrow another trolley jack for the front.

Having said that it is not the kind of job i'd recommend doing on your own,as they are very heavy.

[marky]

I only dared tackle it after reading Les hensons thread on how to do it on lr4x4, he makes it sound so easy. But then again I'm sure that experience has got something to do with it!!! Before having the disco I'd only ever changed brake pads and other fairly simple jobs. Maybe that's what is meant by 'the land rover experience'!!

[marky]

All back together now (apart from the interior) and its all good, apart from the pedal! Press the pedal to the floor and thats where it stays! I've bled the hydraulics but that has made no difference. I wish I'd checked the selector fork a bit more thoughly now! Is that likely to be the problem? Somehow I don't think I'll be going to Billng now :'( 

[chris9119]

I only dared tackle it after reading Les hensons thread on how to do it on lr4x4, he makes it sound so easy.....

And you think he did it all on his own....!!!!!!!

All back together now (apart from the interior) and its all good, apart from the pedal! Press the pedal to the floor and thats where it stays! I've bled the hydraulics but that has made no difference. I wish I'd checked the selector fork a bit more thoughly now! Is that likely to be the problem? Somehow I don't think I'll be going to Billng now :'( 

I'd have gone with Dr Neil, sounds like the "Fork" isn't with you...., looks like it's all got to come out again. Lesson to be learnt, for the few quid that the parts inside the bell housing cost, change them all, everytime.....

[Sharpshooter]

This is what happened to my mates one. If you look. You can see where the arms have parted.
The falcrum that normally wears was ok. This was not a genuine part. The clutch had been in for only 18 months. I bought a genuine one when i did mine. It was £20 with the small plastic clips.

[marky]

Its took me three weeks on and off,and it took two attempts but I've done it   :D :dance:.
I managed it all by myself with a bit of help from Mr Haynes, Mr Henson and of course you chaps who have posted on here, thanks for the input.
I don't really know what the problem was, all the bits looked ok, but I've replaced everything and it works a treat.
Now I hope something else does'nt go wrong before the show at Peterborough, Ive missed the Breckland club family weekend, and Billing show so far.
I have quite enjoyed doing all the work on the Disco, but it's much more fun driving it!