DMF and clutch change Monday, what to check?

Hi fellas,
changing the DMF, clutch and roll pins on my 1995 DT manual on Monday. Anything else that should be done when I'm in there? Oil seals?

Cheers,
Crt

It is quite a major piece of work getting it all out and you don't want to do it again in a hurry. Check the VCU before you start in case you need to do that.

You might want to try and get a second set of roll pins up the first set. They're crap! I managed to jam a pop-rivet stem in there.

I never changed my release bearing but some people might recommend it while it is off? Someone like JamesMartin is good on gearboxes.

You might as well do the gearbox oil. Some will drop out with the gearbox cooler pipes anyway. If you're going to do that you might as well do the transfer box oil change too. Doesn't take long. New copper washers on the drain plugs. Grease the propshafts while they're off too. Much easier!

Maybe handbrake and gearstick gaiters too?!

I changed my clutch slave cylinder when I did mine because the old one popped clean out when my spiral clutch pins broke (see comment above!)

Have some green Loctite on hand in case any of the bell-housing studs act up. Very easy to overtighten and polish the threads out.

Incidentally, what are the symptoms of the failing DMF? Let us know what it is like when you've fixed it all! Before and after videos might be nice!

Grrrrrr said:

Incidentally, what are the symptoms of the failing DMF? Let us know what it is like when you've fixed it all! Before and after videos might be nice!

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Don't know on the P38, but on the Transit, crunchy gear shifts, rattling sound, strange vibrations and a fecked starter motor, full of rubber dust from the DMF. I replaced it with a solid flywheel it's made a big difference to gear shifts.

Datatek said:

Don't know on the P38, but on the Transit, crunchy gear shifts, rattling sound, strange vibrations and a fecked starter motor, full of rubber dust from the DMF. I replaced it with a solid flywheel it's made a big difference to gear shifts.

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Perhaps I should have said, what were your symtpoms?!

Mine's bound to fail one day. Same age as his and same car!

DMF = work of the devil

Datatek said:

DMF = work of the devil

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Prices certainly are. I assume it is there to take vibration away from the gearbox and make it quieter.

Grrrrrr said:

Prices certainly are. I assume it is there to take vibration away from the gearbox and make it quieter.

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It smooths out the drive especially at low revs and also absorbs shock from clutch misuse as I understand it. certainly the Transit is less smooth pulling at very low revs, the answer being to downshift

Thanks for the answers! I'll change the oil in both Tbox and tranny, slave cylinder was rebuilt last year after it blew spectacularly.
I'd appreciate some more debate on changing the release bearing, as it is probably wise to do that too, if I take the thing off.

My clutch and DMF are both fecked, so I don't know if one is the reason for another, but generally speaking the symptoms are:
- rattling from clutch area when idling,
- rattling when on tickover,
- jerky ride around tickover speeds (that could also be due to slack in the driveline)
- clutch slips in 3rd an 4th gear when turbo kicks in. Slips big time, so you have to accelerate gently.

Thought of doing it myself (noone around here wants to deal with RR repair so i usually do my own repairs), but since I have no suitable hard surface to put a garage jack underneath the tranny and move it, a friend will do it on his pit.

I was lucky I guess.. got a mislabeled P38 DMF sold as a regular flywheel, for a price that matched the description - 40 GBP. The thing is still inside manufacturers tolerances for new flywheels, so i guess i have a winner. Clutch set (valeo) was about a 100 GBP.

I'll try to do some video of before and after.

Grrrrr, what mileage are you on? I'm still on the first DMF with 345k km on the clock...

chort said:

Grrrrr, what mileage are you on? I'm still on the first DMF with 345k km on the clock...

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130k miles. Think that works out at about 208k km?

The gearbox and transfer box together is pretty heavy. I used 4 poster ramp and a transmission jack with an adapter to bolt it to the gearbox. Was tricky getting it lined up to get it back in (make sure the clutch pedal is all the way to the floor on reassembly).

People have done it on here in car-parks using lorry straps and trolley jacks. Rather them than me though!

You won't want to take it apart in a hurry so make sure those spiral pins are good and I guess you might as well do the release bearing at that mileage.