Member Since: 30 Apr 2006
Location: Eire
Posts: 1333
Fitting a new clutch
Though that some might like to see these. As you know my clutch was acting up (slip and parkbreak lights on)
Local Dealer wanted 1900Euro to do the Job ,
With this mind I said I would give it a go along with a few friends. BIG BIG Thanks to The Large One who once again came to my rescue with a new clutch , a new fly wheel and a new release bearing. (I got the fly wheel and bearing just in case)
Also Nick at great pain scanned in and emailed me over the " how to " for the various parts
Below are some pics of how Im getting on ,
Drive shafts and guards removed ,(you dont have to remove both drive ends it was just easier)
Click image to enlarge
Heavy b d , mother of a gear box to get out , removed a few plugs from loam , two breather pipes
a gear shift link pin and clamped off a hose going to the release bearing ,
Click image to enlarge
release bearing looked ok but we replace it with a new one , 2 min job , two bolts .
Click image to enlarge
The bit I wanted to see , clutch in , 107K Kms worth of permagrine
Click image to enlarge
Click image to enlarge
Back of engine with fly wheel removed
Click image to enlarge
The old and the new , Once again Like the release bearing it looked fine but we replaced it
Click image to enlarge
New Fly wheel installed ,
Click image to enlarge
Next align and fit the clutch
Click image to enlarge
We managed to get the gear box back together this morning and mount it up on the new clutch
once again a heavy job , 14 bolts hold it in .
Thats as far as we got , connect up the wires , reinstall the drives and guards , bleed the clutch
and pray it works.
Watch this space ..
22nd Sep 2009 1:14 pm
Popelka
Member Since: 31 May 2008
Location: Praha (Prague)
Posts: 2430
I always thought it was best practise to change release bearing when change the friction plate (clutch);
looks hell of a job that though how many mates did you say you had help from as that gearbox looks kind of big Experience is a difficult teacher, because she gives the test first and then the lesson afterwards!!!!
22nd Sep 2009 1:37 pm
wiggs
Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372
Great job Barry
I know what sort of jobs involved now mines out of warranty as of today ( not that my clutch has gone ..but you never know )G4 Gone ...but not forgotten
22nd Sep 2009 1:53 pm
DigitalJunior
Member Since: 22 Nov 2008
Location: Cumbria
Posts: 4401
As you may know I have recently had a new clutch, flywheel, XYZ switch AND gearbox. No effort on my part as dealer did the work but ouch my pocket hurts.
In fact they had the gearbox off and on three times as to start with the new flywheel was faulty but they couldn't work out why.
Hope yours goes back together okSOLD - 23my Range Rover Sport D300 Dynamic SE
Wow, you hand yer money out that clutch TLO has left the building.......
I no longer work for a Landrover Dealer
My little chilli sauce business http://www.thechillees.co.uk
if you would like to order anything just give me a shout
22nd Sep 2009 2:42 pm
tanters
Member Since: 24 Oct 2007
Location: Oireland
Posts: 4287
Nice job Barry
Go easy on the ol doll for the next 100k eh A happy childhood ... is the worst possible preparation for life.
22nd Sep 2009 3:10 pm
BarryG
Member Since: 30 Apr 2006
Location: Eire
Posts: 1333
Got her all back together and it worked 8)
The only problem is that I still have the park break fault and missing gear numbers from the dash ,
I think like the last time this is a dealer reset on the XYZ Box to clear the fault. So I need to visit the dealer .
or does anyone know of a way to reset this ?
All in all the job is not that bad to do your self ,but you do need the tools and the people to help with the lifting.
also the tech diag's from Nick .
A bit of pain Ok .... but considering the money I saved
22nd Sep 2009 6:41 pm
BarryG
Member Since: 30 Apr 2006
Location: Eire
Posts: 1333
The Large One wrote:
Wow, you hand yer money out that clutch
Well cooked ..
Cheers again Nick .
22nd Sep 2009 6:46 pm
wiggs
Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372
Barry ..you can try and calibrate it yourself
Found this
Start in reverse then each forward gear, hold each gear with foot fully off the clutch until the gear indication shows the selected gear, this must all be done in one ignition cycle. Once complete turn ignition off and remove key until the radio clock & park brake indicator go off.
You can also do this in low ratio ..saves finding a long road ..you need to get the reverse gear up first on the dashG4 Gone ...but not forgotten
22nd Sep 2009 6:55 pm
BarryG
Member Since: 30 Apr 2006
Location: Eire
Posts: 1333
Cheers Wiggs I give that a go
22nd Sep 2009 6:59 pm
bellautos
Member Since: 02 Feb 2006
Location: NorthYorkshire
Posts: 2532
Nice work and good pictures.
Did you manage to locate the gearbox wireing loom in its original position ok with the silly little clips, we had one in that had a clutch fitted and the loom was not reinstalled correctly and melted with the heat from the side to side exhaust pipe
It caused no end of electrical problems when in melted state.
Also the pipe was not fitted back correctly and had split due to viration on the flexi part of it.
Not a nice job to fit with the gearbox in the way.
Not to bad to do in my defender tho lol.
Pete
22nd Sep 2009 7:25 pm
Wex
Member Since: 16 Apr 2007
Location: Knackeragua
Posts: 5173
Maith an Fear B
Ed:give us a shout when you're doing the XY sensor recal
22nd Sep 2009 8:21 pm
BarryG
Member Since: 30 Apr 2006
Location: Eire
Posts: 1333
Wiggs that worked , fault cleared No need to go to dealer now .
I was delighted when the light went out an the numbers on the dash came on . I was a small bit worried about this
thanks again
Pete : Cheers for the advice ,, to answer your question .. i think so It so tight up in that space its very hard to see once the box goes back in . Im going to check her over again on the driveway this week end just make sure. Im happy enough but just to make sure
DW : Sorry , I had it done on the way home before i got your PM. Im going to Dublin in the morning I'll give you a call while Im on the road.
22nd Sep 2009 9:22 pm
Wex
Member Since: 16 Apr 2007
Location: Knackeragua
Posts: 5173
You cannot post new topics in this forum You cannot reply to topics in this forum You cannot edit your posts in this forum You cannot delete your posts in this forum You cannot vote in polls in this forum
,
d , mother 
mines out of warranty as of today ( not that my clutch has gone ..but you never know )
It so tight up in that space its very hard to see once the box goes back in . Im going to check her over again on the driveway this week end just make sure. Im happy enough but just to make sure 
