Clutch replacement

[dazzzer1]

just a a pointer for the future, not too soon i hope. but you dont need to remove the box, you can leave the drive shafts connected and just undo the rear mount and the bell housing, you then need to support the enginethere is ample room to remove and replace the clutch

[lamb125]

Thanks for the tip guys. I spoke to a mechanic at the college where I teach today who suggested the same tactic. He said that bearing makes a huge difference when it comes to clutch operation.

[Ian Hulley]

It's the lobe on each of the operating forks that makes a HUGE difference

[lamb125]

The bite point of the clutch before the problems started was very high by the way. It was like this after I replaced the clutch slave cyclinder several months back. I hadn't noticed this before. Would having worn lobes contribute to that high bite point? Clutch plates have plenty of friction material left on them incidently.

[lamb125]

The job is done, but not without sheding blood, sweat, tears and ample cursing! The hardest part was offering up the gearbox and relocating it - not easy on your own with blocks of wood and trolly jack. Anyway after realigning the gear linkage bracket on the gearbox spline all is fine, in fact the gears have never been smoother to change. Test drove it yesterday for around 30 miles with no immediate problems. Happy again!

[CovKid]

Tell us about it. Most of us have the T-shirt and the busted fingers to prove it. Took out and replaced Corkyboy's gearbox on a busy road in Manchester whilst laying in a puddle. When it won't go back in even after two hours you lose the will to live - then one end works its way off the piece of wood you'd placed precariously and you need arms like Popeye in a cramped space beneath. In desperation I used cramps and slightly longer bolts to put enough preload on it to persuade friction plate to line up with splines on shaft. Not exactly by the book but it did the trick, requiring a gentle kick to push it home. Beetles are worse as you have the axles attached if you have to get the box out

Way, way easier with the vehicle on a hydraulic lift with 11 mates to help you

The hardest part was offering up the gearbox and relocating it - not easy on your own with blocks of wood and trolly jack.

[cherl889]

Tell us about it. Most of us have the T-shirt and the busted fingers to prove it. Took out and replaced Corkyboy's gearbox on a busy road in Manchester whilst laying in a puddle. When it won't go back in even after two hours you lose the will to live - then one end works its way off the piece of wood you'd placed precariously and you need arms like Popeye in a cramped space beneath. In desperation I used cramps and slightly longer bolts to put enough preload on it to persuade friction plate to line up with splines on shaft. Not exactly by the book but it did the trick, requiring a gentle kick to push it home. Beetles are worse as you have the axles attached if you have to get the box out

Way, way easier with the vehicle on a hydraulic lift with 11 mates to help you

The hardest part was offering up the gearbox and relocating it - not easy on your own with blocks of wood and trolly jack.

I did mine mine on my own ....it was crap...gravel drive way ....trolley jack....wood....lots of swearing, but cut the input shaft off of the knackered gearbox I was taking out and used it as an allignment tool..took me two days.

Mark

[lamb125]

I think the 80-90 club should issue a special 'I changed my own gearbox and lived to tell the sorry tale' tie, or something perhap more fitting! Just spent an hour removing a very stubborn nut on the handbrake rod, it must have been loctited on, had to saw it off without damaging the thread and now I've fitted a new nut and taken up some of the slack - much better!

[Realize]

Hi

I had same trouble last year, the guys on here helped me out no end.

My spiggot bearing had collapsed also and caused a lot of scoring to the flywheel so I had it machined, I also changed the gearbox oil seal.
The input shaft was also messed up so i spent an age smoothing it down with wet and dry so it was all smooth again.

And I did this on a sloping drive using a motorcycle jack and a trolley jack, damn near killed me I could not do that again on my own.

Good luck you should have no problems if you listen to the great advice from this forum.

Jay

[lamb125]

I made up a wooden cradle (picture a heavy duty picture frame with casters on each corner) to support the gearbox, slid it under and then jacked up the gearbox from the middle of the cradle and then stacked blocks of wood on the cradle as I got it to height. Was relatively easy up the alighment bit. At one point everything slipped and my heart sank thinking I've bent the splined shaft! Luckily it must have just been clear of the spline in the friction plates not have located. Spent a lifetime actually locating the damn thing and used slave studs to help guide it on. I also was working on a sloped driveway, laying on a damp (rained the night before) piece of carpet to cushion the bruising. Went out that night and had a few large ones!!