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#Post#: 73838--------------------------------------------------
Cheapskate clutch change
DIR By: lister
Date: September 8, 2013, 12:39 pm
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Having found myself with no clutch I found myself in a position
whereby I either fix it myself or get used to walking instead of
driving.Having nothing to lose I decided to get on with it.
I took out the seats,floor plates and gearbox tunnel to get
access to the gearbox from above,then unbolted both propshafts
(gearbox ends only) and unbolted the gearbox to chassis mounts.
I unbolted the slave cylinder and pulled it out of the way.
It was fairly obvious that the overdrive would need to come out
if the gearbox was to come out,but that just unbolts and pulls
away from the main gearbox.
The overdrive is a lot heavier than it looks and greasy as
hell,and was a bit of a fiddle getting out from above (nearly
dropped it).Didn't bother to drain any oils,wasn't a problem.
I put a 2 foot long plank under the gearbox and lifted the
engine slightly to get it under the engine,then dropped the
engine back down to sit on it - holding the engine in position
when the gearbox comes off,and to act as a guide for the gearbox
to slide on later on its journey off and then onto the engine.I
put a bottle jack under the other end to hold it up.
Next I cut a length of 4x2 timber to fit across the inside of
the roof gutter and put it in place,making sure it was free to
slide back and forth.This is to take the weight of the gearbox.
[IMG]
HTML http://i481.photobucket.com/albums/rr174/snaggletoooth/Clutchchange3.jpg[/img]
I tied some old rope around the gear lever bracket,and around
the handbrake drum and slung a couple of cheap ratchet straps
over the timber and hooked onto the rope slings,tightened up the
straps to take some weight.
Next is just to remove the gearbox bellhousing to flywheel
housing bolts,then tighten up the ratchet straps a bit and pull
the gearbox back off the engine.I tapped each end of the
supporting timber with a mallet in turns to move the gearbox
further back and give me room to work.
[IMG]
HTML http://i481.photobucket.com/albums/rr174/snaggletoooth/Clutchchange1.jpg[/img]
Ordinarily at this point you'd just undo the nuts holding the
clutch cover to the flywheel,but one of my bolts went round and
round instead of unscrewing,I first tried a sharp chisel,then
ended up using a dremel type tool with a cutoff disc to cut the
bolt to get the clutch cover off.
I had to take off the starter motor and remove the flywheel to
replace the offending bolt (bolt fits in from behind the
flywheel),then put flywheel and starter back on.
The clutch plate was well worn,but not down to the rivets,it
turned out my problem was that the diaphragm spring in the
clutch cover had snapped in half,top and bottom (at about 11
o'clock and 5 o'clock in the pic).
[IMG]
HTML http://i481.photobucket.com/albums/rr174/snaggletoooth/Brokenclutchspring.jpg[/img]
Due to lack of funds I replaced the friction plate and clutch
cover with lovely Britpart items,and replaced the well worn
release bearing with a better used one I'd had free with one of
my collection of broken gearboxes.
I rummaged through my socket set to find the best fit into the
spigot bearing in the centre of the flywheel,and wrapped a turn
of tape aound it to get a good fit,then used this to centre the
friction plate whilst the cover plate was bolted down,making
sure the flywheel dowels lined up into their holes in the cover.
I fitted the release bearing onto the gearbox shaft and hooked
the plastic clip over it from the release arm.
The gearbox went back on without much fuss,just a matter of
fiddling with the ratchets to get it all level,and tapping the
timber forward with a mallet until it slots together,and it was
then just a matter of bolting everything back together again.
Piece of cake really.
The clutch now feels a lot lighter than it did before and
actually works just fine.
So there you have it,I know I'm not the first person to do a
clutch change this way,but I just wanted to show that it's
possible for anyone to do,you don't need to be built like a
gorilla,or have any expensive special equipment to get the job
done.
#Post#: 73841--------------------------------------------------
Re: Cheapskate clutch change
DIR By: 474
Date: September 8, 2013, 12:48 pm
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Top spannering, an excellent way to spend Sunday and the
tradition way to swap a clutch. I read an article once about a
quarry company who used to fit Perkins 4203s to their series
fleet which often saw heavy towing. The clutch procedure that
you have ably illustrated here was so common that they modified
how the floors and tunnel fitted so that that particularly
time-consuming job was less of a hassle.
:thumbs:
#Post#: 73852--------------------------------------------------
Re: Cheapskate clutch change
DIR By: hippydave
Date: September 8, 2013, 1:31 pm
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making my seatbox quick removal for just such an occasion
#Post#: 73891--------------------------------------------------
Re: Cheapskate clutch change
DIR By: gp3trainee
Date: September 8, 2013, 10:04 pm
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Thanks for an excellent guide.
#Post#: 73906--------------------------------------------------
Re: Cheapskate clutch change
DIR By: Time Bandit
Date: September 9, 2013, 5:34 am
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Nice one! Brings back happy (hmmm...maybe not!!) memories of
doing mine in a similar fashion but without the wood across the
top to take the weight of the 'box!
#Post#: 73915--------------------------------------------------
Re: Cheapskate clutch change
DIR By: lister
Date: September 9, 2013, 8:12 am
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Thanks for the replies,I just wanted to show how easy it can be
when things go (relatively) right.
#Post#: 77679--------------------------------------------------
Re: Cheapskate clutch change
DIR By: serious
Date: October 20, 2013, 7:54 am
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well done
#Post#: 77718--------------------------------------------------
Re: Cheapskate clutch change
DIR By: Lucy
Date: October 20, 2013, 1:31 pm
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Just a note, the box can come out with the o/d still attached,
just makes it a little heavier.
Bet you're feeling quite satisfied and justified of your ale
quaffage now :-)
#Post#: 77760--------------------------------------------------
Re: Cheapskate clutch change
DIR By: lister
Date: October 20, 2013, 6:26 pm
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"Just a note, the box can come out with the o/d still attached,
just makes it a little heavier. "
I took the overdrive off because I'd not have been able to move
the gearbox back far enough to get at the clutch and flywheel
otherwise. :smile1
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