blackwolf wrote:

Unless you are paying someone and are very tight for money, it is a false economy to keep the transfer and main gearboxes bolted together when doing this job. One of the main weaknesses of the Puma transmission the output adaptor shaft splined coupling between the two gearboxes, and it would be pretty daft not to inspect it whilst you have the transmission out. Separating the two boxes also makes them much easier to handle, so really it is what the young folk of today would call a win/win situation.

I have replaced my clutch several times (it is a Puma, after all) and it needs doing again, and every time have done it outside on my tarmac driveway (which is a pain since you have to use a board under the jack so it doesn't sink in the tarmac) working on my own. It is really not difficult, but does require a certain amount of care since dropping either box on your noggin or other squashy bits will cause injury, possibly life changing, and could damage the gearboxes of course. The first time I used a trolley jack, subsequently I bought a transmission jack since it is better suited (it has a wider stance and a flat plate which can be tilted in two planes to make alignment easier). It is very helpful to obtain (or fabricate) the LR special tool for lifting LT230s, this bolts onto the bottom cover plate and provides a flat and level surface for the jack to lift. It is pricy to buy but dead simple to make.

The R380/LT230 assembly is easy to remove as a single lump, and there is a similar tool available to allow the complete transmission to be safely jacked (again pricy to buy but easy to copy). There is, unfortunately, no equivalent for the MT82/LT230 combination, which is another argument for splitting them. There is no off-the-shelf bracket for jacking the MT82, but most transmission jacks are designed to accommodate gearbox-shaped objects so this is not usually a problem.

So in summary, I think you would be daft not to split the LT230 and MT82 on any Ford-engined Defender, it is entirely possible for one person to do a clutch change outside without a lift and on their own. and using a transmission jack makes it much easier to control the parts you are removing or refitting. I also completely agree that buying the proper extractor for the spigot bearing on the Duratorq engine is worthwhile, it will help prevent swearing, personal injury, mood-swings, and other likely side-effects.

Just my opinion of course, other opinions are available!

tristanpowter wrote:

Thanks for all the help above - going to attempt to replace the MT82 with LOF adapter and fit LOF Clutch at same time myself on the barn floor!

Does anyone know if there is a step by step guide any where to do this?! I'm ok with most mechanical jobs but this is a step above anything I've done so far. Have a full set of tools including trolley jack but may invest in a transmission jack to help drop it out.

Any pointers be much appreciated!