Disco 1 Clutch & transfer box labour query

Hi guys,

Generally I'm happy to have a go at anything on my Disco (300tdi), but changing a clutch and replacing the transfer box aren't things I want to tackle - I've picked up a transfer box and they are bloody heavy. Cannot imagine how heavy the gearbox is!

Roughly, how much do you think I would be looking at to have the clutch replaced, and the transfer box swapped out for a different one?

I would supply all parts myself, which I believe would just be the clutch kit & fork, and the seals for the transfer box (and of course the replacement transfer box itself).

Cheers.

Foz

Plus oils and consumables, but as for labour... well that will depend on who is carrying out the work, so rate RH, the duration of the job and overheads. So why not get quotes for the job and take the best of the three.

What he said. Couple of people who know what they're doing, and have equipment to help, a couple of hours. Couple of mates who think they know what they're doing, four hours+ .. A lot of it can be faffing about, cleaning the cow **** etc ..

fozt said:

Hi guys,

Generally I'm happy to have a go at anything on my Disco (300tdi), but changing a clutch and replacing the transfer box aren't things I want to tackle - I've picked up a transfer box and they are bloody heavy. Cannot imagine how heavy the gearbox is!

Roughly, how much do you think I would be looking at to have the clutch replaced, and the transfer box swapped out for a different one?

I would supply all parts myself, which I believe would just be the clutch kit & fork, and the seals for the transfer box (and of course the replacement transfer box itself).

Cheers.

Foz

Click to expand...

You are right the whole lump is extremely heavy, I cannot tell you what it would cost to have the job done. But can imagine it's expensive.
I have replaced the clutch in mine myself, working from above through the top of the tranny tunnel and supporting the whole lump on a special gantry arrangement sitting on the front floor in front of the seats, I built it out of steel RHS threaded bar and a piece of chain, using that device and working entirely unaided in a small garage off the floor for the underneath stuff, I had the whole job done in about 10 hours start to finish, including removal of 3 or 4 broken off bellhousing bolts.
I have also used the same rig on a mates Disco 1 to pull out the transfer case only on its own to replace the intermediate shaft seals, not sure what time that took as we were doing a rebuild on the front axle whilst doing the other stuff.

Whenever I think about the clutch on the Disco, I have to remind myself that a Morris Minor it ain't.
My thinking would be that you only want to go in there once in your life, so replace the lot, thrust race, fork, clutch pressure plate and housing, friction plate and crankshaft oil seal.
As to time and costs, I've no idea, but I've attached the LR Main dealer's advisory times from the D1 RAVE which might give you some idea.