Diahatsu DG engine/clutch question.

Chockster · Mar 10, 2021

I have a series 3 ex army 109 I’m refurbing it all but by bit. It has a diahatsu 2.5 dg engine conversion but original gear box. Now I have the seat box and floor up I think it’s a good time to change the clutch. My question is quite simply...

is the clutch an engine component or gearbox component. I need to know what to order. Weather it be a diahatsu clutch kit or the landrover

any info would be appreciated.

many thanks

Kev12 · Mar 10, 2021

I dont know the answer but logic says it could be LR clutch and daihatsu pressure plate.
Safest way is strip it to find out and remember to either replace clutch arm for a HD one or weld a brace on the std one yourself

Chockster · Mar 10, 2021

For what reason would it need to be heavy duty? Also do you have an illustration of what to weld to bolster the clutch arm?

Blackburn · Mar 10, 2021

Clutch arm problems are a defender issue not a series.
What gearbox is fitted? Photo's would be good.

Chockster · Mar 10, 2021

Here is the gear box...
Also should I be concerned the way it’s married up to the bell housing or irks this standard practice for the DG conversions?

tottot · Mar 10, 2021

It is just a fact that the housings are a slightly different shape. An adaptor plate is needed for most other makes engine swap but in this case it ;looks like they are close enough.

Blackburn · Mar 10, 2021

That's a series 3 gearbox the clutch actuating arm is very strong no issues will be had with that.
The only way to know whats fitted is to seperate it and post some pics you could possibly remove gear lever assembly and have a look through the hole below it hard to take pics without a probe type camera.
Have you tried searching on line for advice on converting a landrover to that engine it used to be popular.
I had a 4 track before I got back into landrovers and if I known at the time you could fit the engine in a landrover I would have kept the engine as it was very efficient.

rob1miles · Mar 10, 2021

Measure the dia of the plate. Std series is 9" but there is an HD one at 9.5" and my with a 3.3 Perkins has a 10". Its possible they fitted a bigger clutch as part of the conversion, that's what seems to have been done to mine so assume nothing.

Kev12 · Mar 11, 2021

Blackburn said:
Clutch arm problems are a defender issue not a series.
What gearbox is fitted? Photo's would be good.

You are quite right of course, I didnt even know I had strayed to the Series forum

Chockster · Mar 19, 2021

Hello again. I finally found the time to lift the gearbox out and take the clutch apart. Here are some pictures of the wear plate. Does anyone know if this is Land Rover or diahatsu???

Chockster · Mar 19, 2021

Here are the pictures

nathanglasgow · Mar 20, 2021

Chockster said:
Here are the pictures

A quick Google of the visible part number says its a Land rover clutch disc.

Chockster · Mar 21, 2021

Ha ha would you believe I didn’t even see that!! perfect thank you.

Chockster · Mar 21, 2021

Now I’m thinking it probably has a diahatsu pressure plate fitted as it fits perfectly to the flywheel and a LR clutch plate. I’ll post some further pictures for advice on the pressure plate. Problem I’m having is grinding as going in to gear as if clutch is not depressed properly. Also disengaging 4 wheel drive is sometimes impossible!

Kev12 · Mar 21, 2021

The 4wd issue isn't clutch related.
For the grinding, unless the fingers are worn on the pressure plate its probably a hydraulic issue. Was there a lot of free play on the pedal?

Chockster · Mar 21, 2021

Yeah fingers seem a little uneven on the pressure plate. My Hanes manual said it was clutch rather than gear box. What should I look for in the hydraulics there doesn’t appear to be any leaks. Probably just needs bleeding.
Here is the pressure plate. It appears to be a bork and beck 9 1/2” I just can’t get my head round the fact that a stock landrover clutch kit would marry to a Japanese flywheel seemingly without modification???

rob1miles · Mar 22, 2021

Its usual to use the friction plate that matches the gearbox spline. What would be really odd is if the Jap plate fitted the LR box. The std LR plate is 9", you can get a 9.5 HD one and mine has a 10" which I think came of a Jaguar.

Diahatsu DG engine/clutch question.

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