Clutch system total replacement - any advice?

Hello there!

I'm going to be replacing all the clutch related components on my 200tdi defender 90. The Haynes Manual recommends taking out the engine rather than the gearbox, to gain access to the clutch - apparently this is an easier job!?

So far, here is a list of the things i think i will be needing:

Clutch kit - AP driveline (formerly beck & borg) includes plate, cover and release bearing (from paddock's)
clutch arm (havent found anyone selling these yet)
Clutch master cylinder - from paddock's, the lucas one - cant find geniune girling anywhere!
Clutch slave cylinder - as above

sealant for bellhousing
gaskets for clutch pedal box and small panel on top of clutch pedal box

rubber grease
coolant
brake & clutch fluid
power steering fluid

Can anyone think of anything else i'm likely to need? is a clutch alignment tool essential?

Also, while i have the engine/clutch out, is there anything else i should consider replacing or inspecting?

I'm still not 100% sure whether it is the clutch itself that has gone or the clutch arm, or the bearing. i do know everything seems to be working up to that point, ie the slave cylinder is operating the pushrod, but the pushrod itself moves in and out without any resistance. I'm fairly clueless about clutches (but learning fast!) but i would have thought that the pushrod should encounter the resistance of the clutch if working properly.

Anyway, since i cant know more until i do actually seperate the engine from the gearbox i figured i may as well replace all the components, considering the amount of work involved!

Any advice would be great... this is the biggest job i've done on my landy so far... so i'm hoping to get it right!

update...

have been looking at paddock's and also famous 4 for parts.

both have a clutch release "fork"... i take it this is the same thing as the "arm"? Famous 4 also have a clutch "arm" slipper pad (whatever that is... do i need one?!)... so a bit confusing

famous 4 one looks more heavy duty and is jet black and i can only assume this must be a genuine part as opposed to paddock's one which is dark grey and somehow looks a bit more flimsy!

i would prefer to get all the parts from one supplier... can anyone vouch for the quality of either suppliers' parts?

well.... end of day 1... have now disconnected everything from the engine, using the haynes manual as a guide - havent followed it to the letter as i'd be there for a week disconnecting stuff that really isnt necessary... not even sure i really needed to take the radiator out completely.. but there you go, its done now!

tomorrow i'll be hoisting the engine out and we'll see what the damage is!

PS anyone know if i need to disconnect the starter motor wiring? or would it be easier just to take the starter off? the haynes just says "all engine wiring" and isnt specific.

Yes the starter is on the engine - so it needs to be disconnected...

The fork and arm is the same thing as you rightly thought.

The slipper pads are what go on the end of the fork on the little pins and act on the release bearing - recover the two from the old fork.

Regarding the fork, the paddocks one will be a flimsy britpart part, try and stay away from britpart. Can you weld? If so weld a small piece of plate on at the back of the pivot point this will make it stronger and it will last longer. Get a small dollop of good quality grease onto the pivot point or else it will wear out prematurely

Hardest part will be getting the engine to slide back fully onto the gear box input shaft. Clutch must be perfectly aligned. I managed this using a small size spark plug socket and some insulation tape. Make sure the rubber engine mounts are fully removed until the engine and box are back together snug as you will need all the room you can get.

When me and me mate did mine we never touched the engine. Had a hoist through the cab, slid back a bit and lowered the gearbox and transfer box onto the floor. It would be a good idea to change the seal under the plate on the gearbox before ye start fitting it all back together and get a heavy duty clutch fork

Thanks for the advice guys!!

just found this on ebay:
Land Rover Defender 90 / 110 Clutch & Fork Kit on eBay (end time 02-Aug-09 20:11:31 BST)

Looks like everything i'm likely to need, clutch-wise!

cheers y'all!