 | Home > Technical > DIY Clutch Change - What Top Tips? |
 
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| Grenadier Member Since: 23 Jul 2014 Location: The foot of Mont Blanc... Posts: 5829   
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Hello all,
I shall soon be undertaking a clutch and output shaft change. I have access to a full size lift and a guy who’s maintained, fixed, recovered etc trucks and HD vehicles most of his life. But can someone please confirm what items I’ll need to think about, any top tips, and cheeky little shortcuts etc. I’ll be fitting a Clutchfix HD Clutch and Ashcroft output shaft. For the clutch, which of these tools do I need? https://www.rld-autos.com/fr/outillage/176...;results=1 https://www.rld-autos.com/fr/outillage/178...;results=1 Also I changed both Trans and Gearbox fluids a month ago, can I keep them if I filter them? And what clutch fluid is recommended? And for the output shaft, there’s some kind of clamp thingy I need. Anyone know what it’s called, where I can find one and whether it is definitely needed ? Think I might be able to borrow one if so. Thanks a always. Monsieur Le Grenadier I've not been everywhere, but it's on my list..... 2011 Puma 110DC - Corris Grey |
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15th Nov 2021 12:49pm |
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| Race.it Member Since: 27 Aug 2019 Location: Algeciras Posts: 823  
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Is there a part number for the drain plugs or maybe a supplier? Next time I change mine I want to put them in.
On the clutch from what I read, not done it you may need a few extensions to get to the top bolts on the gearbox to engine. Also take out the transfer case seperate to the gearbox. Searching for my first Defender...and started just as Covid hit, so talk about timing. 5 months after starting the search I found it, and here is the details |
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15th Nov 2021 2:45pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2031 
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magnetic drain plugs for gear box etc https://www.megasquirt-v8.co.uk/diff_offroad.php
Also https://foundry4x4.co.uk/index.php?route=p...th=65_1758 AS I understand it the gearbox has internal magnets, but I added a magnetic one as the drain. A belts and braces approach which can’t hurt, plus it had a hex head. The transfer drain should already be a magnetic plug. Diffs benefit from drain and fill magnetic plugs as they are level fill. Back to original post, a impact wrench will help remove the bolt securing the output shaft cup to the gearbox. A strong puller , some recommend an hydraulic puller, will help remove the cup off the splines. I expect your helper will have those though. These may help https://www.youtube.com/watch?v=dPFUyCVNQGE https://www.youtube.com/watch?v=R4JjSv3NKbg https://www.youtube.com/watch?v=kAFmt_PsYfs Also Nigel’s (Nige - Gloucesternige on here ) landrover channel has some great videos on the gearbox https://youtube.com/c/Defender90KeswickNigelsLandRoverchannel |
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15th Nov 2021 7:38pm |
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| Grenadier Member Since: 23 Jul 2014 Location: The foot of Mont Blanc... Posts: 5829
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Thank you all. Makes sense on the fluids, so have ordered some fresh stuff. And I’ll look through all the videos Ian, thanks for the links.
Here’s a photo of the beast being recovered with help from a friend. 
 Click image to enlarge Monsieur Le Grenadier I've not been everywhere, but it's on my list..... 2011 Puma 110DC - Corris Grey |
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17th Nov 2021 8:05am |
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| Leamreject Member Since: 19 Dec 2020 Location: Middle Earth - Leamington Spa Posts: 970  
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Now that is an envious picture… two beauties
 Ride like you stole it!!
If I’m not on a bike it’s because only a 4x4 will do… 2011 2.4 Puma 90 HT |
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17th Nov 2021 8:07am |
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| Grenadier Member Since: 23 Jul 2014 Location: The foot of Mont Blanc... Posts: 5829
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This is a good video as well.
Monsieur Le Grenadier I've not been everywhere, but it's on my list..... 2011 Puma 110DC - Corris Grey |
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17th Nov 2021 8:07am |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2031
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Colour and wheel base coordinated recovery, with both trucks polished and gleaming. Now that’s recovery with a touch of french flair 
. . |
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17th Nov 2021 1:02pm |
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| Grenadier Member Since: 23 Jul 2014 Location: The foot of Mont Blanc... Posts: 5829
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Too kind.
How much Dot 4 do I need for the master and lines? Monsieur Le Grenadier I've not been everywhere, but it's on my list..... 2011 Puma 110DC - Corris Grey |
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17th Nov 2021 1:25pm |
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| Angus_Beef Member Since: 30 Apr 2015 Location: Oslo Posts: 434  
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not much. if you buy 500ml you'll have plenty left over. Get an old fashioned oil can and reverse bleed it. Roaming around 🇳🇴🇨🇭
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17th Nov 2021 1:58pm |
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| piechipsandpeas Member Since: 12 May 2021 Location: Albany, Western Australia Posts: 215  
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Another way to undo the adaptor shaft cup bolt off the gearbox output shaft is to stop the cup rotating with a piece of wood cut to length and fit a suitable sized bolt through at one end that rests in one of the cut-outs on the cup, with the other end resting on the floor of the workshop. Then undo the bolt on the end of the output shaft with a socket suitable sized bar through the hole in the transmission tunnel with the cover under the cubby box removed.
Click image to enlarge Cup is then removed using a suitable puller. |
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18th Nov 2021 11:21am |
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| Grenadier Member Since: 23 Jul 2014 Location: The foot of Mont Blanc... Posts: 5829
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Well, it’s done. Some action shots. It was an OS failure, not the clutch, but that was well gone anyway.
Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Monsieur Le Grenadier I've not been everywhere, but it's on my list..... 2011 Puma 110DC - Corris Grey |
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22nd Nov 2021 7:52am |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3681 
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Nice work!
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22nd Nov 2021 6:53pm |
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| Angus_Beef Member Since: 30 Apr 2015 Location: Oslo Posts: 434
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Good job David
Roaming around 🇳🇴🇨🇭 |
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22nd Nov 2021 7:02pm |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6095 
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I still can't believe how LR get away with this shoddy design (or indeed deny there's any issue)
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22nd Nov 2021 7:08pm |
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