d turbo clutch

[rick30]

Anyone know how big of a job it is to do a clutch on a d turbo?

[Piggy]

3hrs with decent kit and a helping hand...4/5hrs if on own and not done it before

[rick30]

Is there a tutorial on here? Never done a clutch before but am pretty good with the spanners.r

[Tom]

If Chris can do one anyone can (i am so sorry)


But in all seriousness expect it to take a weekend if you haven't done one before then if you catch on quick it shouldnt take that long. If you can having someone who has change a clutch before would be of great advantage. If you can find someone whos done an XUD clutch before, even better.

[Niall]

Yeah if your on your own, the biggest problem for you will be lying on your back trying to get the box back on. Its a complete bastard of a job to do. Much easier if someone can lift it from above then you can lie underneath and guide it in place. They will not go in if they don't go on dead straight!

[Piggy]

raise front of vehicle and support
drain gearbox
remove from wheels
remove driveshafts - note two 11mm nuts holding two retain bolts on engine lower mount which hold one shaft in
remove all the crap around the gearbox, wiring, clutch cable, starter etc
undo the clutch release arm bolt and remove clutch release arm
support engine
undo gearbox mount and remove mount supports
support gearbox - handy friend witha jack
undo all gearbox bolts between bell housing and engine block
remove gearbox
remove clutch
clean flywheel surface
fit new clutch - use alignment tool to centralise
refit gearbox ensuring clutch arm slots onto clutch release bearing

now put it all back together, fill up with fresh oil and have a cuppa T

(worthwhile attaching the clutch arm and cable early on to check it all has aligned ok)

[zx_volcane]

Also worth noting you don't have to undo the hub nuts if you can't / don't want, can just split bottom ball joints and pull them out the way

[WiNgNuTz]

Sorry to hijack your thread, but does anyone have any suggestions as to what one could use as an alignment tool if one doesn't have one?

[THE_Liam]

Something that made my life loads easier last time I did one if you have a strut brace (or a big wooden post laid across the strut towers), loop a ratchet strap around it and use it to support the weight of the box when you're refitting it, loads easier to guide it on when you don't have to hold its weight as well. That and removing the half-shaft under the sump, absolute lady garden of a job.

[Chris_90]

If Chris can do one anyone can (i am so sorry)


But in all seriousness expect it to take a weekend if you haven't done one before then if you catch on quick it shouldnt take that long. If you can having someone who has change a clutch before would be of great advantage. If you can find someone whos done an XUD clutch before, even better.

Its tricky removing the pin for the clutch arm have a spare arm ready just incase you have to bend it, tbh other than that it's all pretty simple. First time I did took gearbox off and found it very easy (apart from 3 hours shouting at the clutch arm) and took about 10mins to get the gearbox back on, on my own all though it is fairly heavy.

Only one way to learn tho just jump in and do it, that's what I do didn't no anything about the 306 tbh before joining here, now can do almost anything. Just in the middle or rebuilding an xud engine now so come a long way.

---

Sorry to hijack your thread, but does anyone have any suggestions as to what one could use as an alignment tool if one doesn't have one?

Valeo clutches come with a plastic alignment tool well the used to, but if not just just a long reach socket with some tape round it.

[Frosty]

Sorry to hijack your thread, but does anyone have any suggestions as to what one could use as an alignment tool if one doesn't have one?

Do it by eye. It aint that bad really. Valeos seem to always come with an alignment tool though witch is handy

[WiNgNuTz]

Yeah, not when it's second hand and part used. Only cost me postage really though, thanks to Tom on here.

[THE_Liam]

I used a bit of mop handle wrapped in gaffer tape.

[WiNgNuTz]

epic pikey Liam, wouldn't expect anything less from you tbh!

[Niall]

Danglyballs, just go to a local garage and ask for one. Most clutches come with a plastic one so garages will have loads hanging about

[WiNgNuTz]

Hmm...good shout sir. Might just do that! I shall stop taking over the OP's thread now though. Thanks for the tips guys!

[rick30]

Selling as spares or repair as I dont have time

[Piggy]

Wingnutz...you can just do it by eye if you cant find one

[WiNgNuTz]

Fair enough, i know a couple of garages round here, so i'll try them first, might go see the guy with the sweet looking Astor 6, and if its there i'll get some pics of it.

[londondan86]

I left the o/s drive shaft in the whole way through, doable but was a bit of a twat to realign at the end!!

[Tom]

Extension with some tape on would work aswell :p