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Fitting a new clutch
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BarryG
 


Member Since: 30 Apr 2006
Location: Eire
Posts: 1333

Ireland 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3
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 Big Cry ,

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 Bow down Bow down

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 Censored d , mother Censored 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 Censored , 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 Thumbs Up
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 ..
  
Post #52335722nd Sep 2009 1:14 pm
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Popelka
 


Member Since: 31 May 2008
Location: Praha (Prague)
Posts: 2430

Czech Republic 

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 Censored big Shocked
 Experience is a difficult teacher, because she gives the test first and then the lesson afterwards!!!!  
Post #52336822nd Sep 2009 1:37 pm
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wiggs
 


Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372

United Kingdom 2015 Discovery 4 3.0 SDV6 HSE Auto Fuji WhiteDiscovery 4

Great job Barry Bow down

I know what sort of jobs involved now Sad mines out of warranty as of today ( not that my clutch has gone ..but you never know )
 G4 Gone ...but not forgotten  
Post #52337322nd Sep 2009 1:53 pm
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DigitalJunior
 


Member Since: 22 Nov 2008
Location: Cumbria
Posts: 4401

United Kingdom 

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 Thumbs Up ok
 SOLD - 23my Range Rover Sport D300 Dynamic SE  
Post #52337622nd Sep 2009 2:03 pm
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The Large One
 


Member Since: 20 Apr 2007
Location: Down the polytunnel
Posts: 6143

England 2009 Discovery 3 TDV6 XS Auto Stornoway GreyDiscovery 3

Wow, you hand yer money out that clutch Shocked Shocked
 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 
 
Post #52339622nd Sep 2009 2:42 pm
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tanters
 


Member Since: 24 Oct 2007
Location: Oireland
Posts: 4287

Ireland 2005 Discovery 3 TDV6 Base 5 Seat Manual Tonga GreenDiscovery 3

Nice job Barry Thumbs Up Thumbs Up Thumbs Up




Go easy on the ol doll for the next 100k eh Wink
 A happy childhood ... is the worst possible preparation for life.  
Post #52340622nd Sep 2009 3:10 pm
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BarryG
 


Member Since: 30 Apr 2006
Location: Eire
Posts: 1333

Ireland 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

Got her all back together Thumbs Up 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 Thumbs Up
  
Post #52353122nd Sep 2009 6:41 pm
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BarryG
 


Member Since: 30 Apr 2006
Location: Eire
Posts: 1333

Ireland 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

The Large One wrote:
Wow, you hand yer money out that clutch Shocked Shocked

Whistle Whistle Whistle Well cooked ..

Cheers again Nick . Thumbs Up
  
Post #52353922nd Sep 2009 6:46 pm
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wiggs
 


Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372

United Kingdom 2015 Discovery 4 3.0 SDV6 HSE Auto Fuji WhiteDiscovery 4

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 Thumbs Up ..you need to get the reverse gear up first on the dash
 G4 Gone ...but not forgotten  
Post #52355222nd Sep 2009 6:55 pm
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BarryG
 


Member Since: 30 Apr 2006
Location: Eire
Posts: 1333

Ireland 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

Bow down Bow down Bow down Bow down Cheers Wiggs I give that a go Thumbs Up
  
Post #52355722nd Sep 2009 6:59 pm
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bellautos
 


Member Since: 02 Feb 2006
Location: NorthYorkshire
Posts: 2532

United Kingdom 2010 Discovery 4 3.0 TDV6 SE Auto Santorini BlackDiscovery 4

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 Sad
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
  
Post #52357222nd Sep 2009 7:25 pm
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Wex
 


Member Since: 16 Apr 2007
Location: Knackeragua
Posts: 5173

Ireland 2006 Discovery 3 TDV6 S Manual Bonatti GreyDiscovery 3

Maith an Fear B Thumbs Up

Ed:give us a shout when you're doing the XY sensor recal
  
Post #52363722nd Sep 2009 8:21 pm
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BarryG
 


Member Since: 30 Apr 2006
Location: Eire
Posts: 1333

Ireland 2006 Discovery 3 TDV6 SE Manual Java BlackDiscovery 3

Wiggs Bow down Bow down Bow down that worked , fault cleared Thumbs Up 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 Thumbs Up

Pete : Cheers for the advice ,, to answer your question .. i think so Confused 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 Thumbs Up

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.
  
Post #52369922nd Sep 2009 9:22 pm
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Wex
 


Member Since: 16 Apr 2007
Location: Knackeragua
Posts: 5173

Ireland 2006 Discovery 3 TDV6 S Manual Bonatti GreyDiscovery 3

no bother , will be on the road from 5 Whistle
  
Post #52372122nd Sep 2009 9:49 pm
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