 | Home > Maintenance & Modifications > DIY clutch change on td5 90 recommendations / help needed |
 
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17320   
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Accepted practice (and the dealer method) is to drop the box out. This is in most ways the easiest and quickest way to do the job, but the problems in the DIY driveway environment are (1) getting the vehicle high enough to drop the box, and (2) managing the weight of the the complete gearbox/transfer box assembly.
It is possible to handle the box safely either by fabricating some sort of flat base which bolts on to it so a jack can be used (the dealer method), alternatively an engine hoist through the cab door supporting the box with slings (after removing the seat box panels and floor panels) works. The main advantage of taking the box out is that noneof the engine connections need to be disturbed, and, if you have it, the AC doesn't need to be emptied and refilled. Since the TD5 has a dual-mass flywheel you probably want to replace it at the same time as the clutch, and I would also change the slave cylinder whilst you have the box out. It is actually not a difficult job, just be careful not to get under the gearbox - it is quite heavy enough to kill you if it lands on your chest! |
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9th Apr 2013 9:57am |
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| amondeggs Member Since: 06 Mar 2011 Location: Telford Posts: 452 
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Ok and thanks for your reply
I was thinking of the engine hoist through the door method tbh. I have 2 car ramps and was thinking of getting another 2 to get a bit more height on the driveway. I think the engine hoist method would involve some work to remove the seatbox and floor panels but would be safer than trying to balance the gearbox on trolly jacks. Thanks again |
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9th Apr 2013 10:03am |
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| Porny Site Sponsor Member Since: 31 Aug 2009 Location: Sutton Coldfield - West Midlands Posts: 806 
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If it was me doing it on the drive...
I would take the engine out if you have a engine crane. A perfect excuse to the give engine bay a proper clean, and new anti freeze etc etc. Intercooler, radiator out, exhaust down pipe off, remove the engine mounts - really not a bad job to do, and IMHO easier than struggling on your back to get the gearbox out. Don't be tempted by a cheap clutch use a Valeo Clutch and flywheel, new flywheel bolts etc. You will have the engine out in a couple of hours... Ian IRB The home of the first modified Keswick Green 90 - and the first 2.4 Puma through both the 200bhp and 550Nm barriers. www.IRBdevelopments.com www.facebook.com/irbdevelopments www.integrated316.com www.facebook.com/integrated316 |
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9th Apr 2013 10:04am |
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| amondeggs Member Since: 06 Mar 2011 Location: Telford Posts: 452
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Engine out method also makes sense but I was reluctant to go down this route as I did not want to disturb the engine and cause other possible problems?
Getting rad and intercooler out will pose no problem as I have just replaced both 
I may be worrying too much? |
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9th Apr 2013 10:12am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5842 
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When I did with mine with help from a mate we dropped the box onto the x-member behind the box and slid it back on this. This gave us enough room to remove the DMF etc and change the clutch.
We undid some of the floor screws as well and the g/box tunnel. Mind the wires on the g/box t/case and the crank sensor. 1999 Defender TD5 110 Regards John M0VAZ Econet Station 48 no clock |
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9th Apr 2013 10:16am |
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| amondeggs Member Since: 06 Mar 2011 Location: Telford Posts: 452
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Ok thanks for that
Just another thing, The flywheel how will I know if it needs replacing? Is it about the amount of play there is ? If so how much is too much? Is is it the case of replace it anyway as you have gone to all the trouble of getting to it? Cheers |
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9th Apr 2013 10:30am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5842
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I had the same thoughts, and thought sod it, I am doing the clutch so will do
DMF along with new bolts Friction plate Pressure plate Release bearing and plastic clip thing Clutch Arm A bit more expensive, but its done now for another load of miles. There is a specific torque for the bolts and done in two stages from what I remember. 1999 Defender TD5 110 Regards John M0VAZ Econet Station 48 no clock |
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9th Apr 2013 11:11am |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6088 
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with just a crane, I'd do as Ian suggests, engine out.
I had to whip the engine out of my 90 the other month (long story... when I built it I put the clutch plate in back to front so it wouldn't disengage...   )
I already had the coolant pipes disconnected, but that's a 10 minute job anyway, so it took me about an hour and half to get the engine to a "ready to lift out" stage, I unbolted the PAS pump from the block, leaving the pipes connected so that saved messing with that. disconnect battery cable, fuel pipes (clip off, easy) a few other little bits, and by unclipping the main loom from the back of the engine, there is enough slack to lift the engine and rotate it about 40 degrees so you can lean over the wing and do the clutch work.  Click image to enlarge |
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9th Apr 2013 2:16pm |
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| amondeggs Member Since: 06 Mar 2011 Location: Telford Posts: 452
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Hi Jim and thanks for the info
It certainly would save wrestling with the gearbox underneath the truck, also like the fact that you did not need to completely lift out the engine, great idea
Thanks again |
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9th Apr 2013 2:59pm |
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| whelo Member Since: 06 Jan 2013 Location: Bridgend Posts: 34 
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I did my mates clutch couple weeks back, we done it from underneath.
I took the transfer box off then the gearbox, its only 6 bolts & couple clips to remove the transfer, with that out of the way the gearbox is easier to handle. I put the front axle on stands & had plenty of room to get in there. & with flywheel, there's plenty of video's on youtube with the amount of play in the dual mass.. Jason Getting there, slowly.. |
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9th Apr 2013 9:05pm |
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| amondeggs Member Since: 06 Mar 2011 Location: Telford Posts: 452
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Cheers for that, did you use trolly jack to move gearbox back? Will have a look at you tube vids |
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9th Apr 2013 9:46pm |
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| SteveT247 Member Since: 21 Feb 2011 Location: Central Posts: 491  
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I can't help with a hoist or anything like that Steve but if you need a hand (and I'm not at work when you do it) let me know and I'll pop over.
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10th Apr 2013 12:42pm |
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