Clutch

Not prety is it! I hope it is enough room, I would have liked to have done this all with more space to see what is going on the first time round, but that is just the joys of car's!

I have already bnought an alignment from Halford made by Laser, hope it is ok.

I did also buy all the bits ans pieces to replace the lot.

Another question is, when I took the slave sylinder off, the pushrod came with it, I assume it is meant to stay on the fork and then push the slave sylinder on after?

James said:

Not prety is it! I hope it is enough room, I would have liked to have done this all with more space to see what is going on the first time round, but that is just the joys of car's!

I have already bnought an alignment from Halford made by Laser, hope it is ok.

I did also buy all the bits ans pieces to replace the lot.

Another question is, when I took the slave cylinder off, the pushrod came with it, I assume it is meant to stay on the fork and then push the slave sylinder on after?

Click to expand...

you'll find a small black clip on the end of the arm/fork that the push rod sits in, yours must of come off when you pulled the slave cylinder off, its' not a big worry, if you have a complete clutch kit there should be a new one, if not, a main dealers 'll have them for a couple of quid, |(thats what i did.)

I think I do have the bits I was just surprised to se it come off.

don't be its a ****y piece of pkastic,
i though the same till i broke mine refiiting it, hence trip to dealers.

Any other tips on refitting it all?

And one other thing, how long do you recon it will take me to fit the clutch and get it all back together, it has taken about 6hours in two sesions so far and I was not working fast at all.

yes,
i'll search out a thread recording some studs in the bell housing that make life easier when closing up the bell housing.
Also been mentioned before but apply grease to end of gear shaft, centre of friction plate. and pivot points of clutch arm.

James said:

And one other thing, how long do you recon it will take me to fit the clutch and get it all back together, it has taken about 6hours in two sesions so far and I was not working fast at all.

Click to expand...

you done well,
TBH, mines still awaiting new master cylinder and i started mine day before xmas eve, and xmas break, bad weather, work commitments, meant i've been ****arsing about with it.
IF you have and manage your time well, you'll be done in another couple of days most.

http://www.landyzone.co.uk/lz/f8/clutch-slave-cylinder-pushrod-thingy-69099.html

if you refit th push rod before you put the bell housing on you won't need this info, but just in case, have it.
more to follow.

can't find the other thread,
but basically what idid to help in mating the bellhousing and engine together,
i purchased two long M10 threaded bolts, and cut them back removing the heads so i had two threaded studs about 5cm long, i screwed these into the lower boltholes on the engine side, by hand, and they then aided me in repositioning the bell housing ,
once sucessfully on i tightened them up with nuts, rather than removing and replacing original two bolts.

a freind helped me with the weight and ideas at this stage, and he also discovered turning the front prop flange, enabled us to correctly mate the input shaft splines into the centre of the clutch, before this we were really struggling ,to get it on, after discovering this, thirty seconds, click, slide, in!! socket set out nuts and bolts tightened, remount gearbox mounts, slave cylinder, bleed,propshafts back on, exhaust back,done(in theory).

That makes sences cheers.

The reason I am getting on with it is that it is my daily drive so Icould realy do with it back on the road, fortunatley I am borowing a 90 of my uncle to get me arround at the moment.

i've edited my last post and added a few more tips fyi.

Just that thanks, sound easy doesn't it.

Why did you bleed the clutch if it has not been disturbed?

i had to bleed mine because when i was checking for the fault i removed the master cylinder, which turned out tobe knackered anyhow, you won't need to if you've not let air into the line, i forgot that.

Thats cool, just checking. No I left mine well alone just unbolted it.

Well another 2 1/2 hours and I have the old clutch out, the new on in and closed up the gearbox to the engine, just need to bolt it up and put everything else back now. Realy not as bad a job as it sounds.

In the end it turns out it was the thrust bearing that was totaly shot.

Gotoneatlast, I used your idea about the thread except I used stugging and cut about 2x150mm and used them, this gave me flexibility to bend them slightly to get the gearbox started then it slid long untill it met the others then a bit more shuffling and I was there.

James said:

Well another 2 1/2 hours and I have the old clutch out, the new on in and closed up the gearbox to the engine, just need to bolt it up and put everything else back now. Realy not as bad a job as it sounds.

In the end it turns out it was the thrust bearing that was totaly shot.

Gotoneatlast, I used your idea about the thread except I used stugging and cut about 2x150mm and used them, this gave me flexibility to bend them slightly to get the gearbox started then it slid long untill it met the others then a bit more shuffling and I was there.

Click to expand...

thats good,
i picked up the tip from some one on here, so pass it on( ican't remember the guys name???<sorry, but thanks)

did you swap spigot bushes?

No could not work out how to get it out, to be honest everything else looks ok except the release bearing, the fork was in perfect condition and the clutch looked ok to.

good,
rivetted the centre cover back on mine todaqy only to find a rubber seal i'd forgotten to place under the gearstick box/cover, hanging over the handbrake,
i dunno what to do, i ****ed around for ages today drilling out old rivets, punching in new ones and hitting others with a drift,
FK me, its never ending!!

Interesting point, mine were all screwed not riveted, it must have been a stupid change between the 200 and 300tdi's