Clutch Day Tomorrow

Best_of_British · 27th October 2013, 17:03

Well the day has come, tomorrow after my nightshift I will be starting clutch replacement, about the same time the worst storm for years hits our shores, sods law.

I plan to replace clutch plate, pressure plate, CSC and fit new Tazu master cylinder and take a few photos in the process. Thanks to FrenchMike for his Howto and some good advice from DAS68 who has recently done his I feel confident enough to attempt it.

Due to the inclement weather expected and the hours I will be awake. The first day will be taking it easy, I hope to get the car safe to work on clear space to work on the box from above by removing FBH, battery tray and starter motor. Underneath I will get the tray off and drop the gearbox oil and hopefully get the old master out and Tazu one in. On the Tazu I am going to stick with the copper supplied and see how it goes.

I think that will be enough for a start and a good nights sleep will enable me to tackle the serious graft on Tuesday. I hope to complete it in 2 to 3 days but best laid plans and all that. I will take some photos of how I get on and post them on this thread.

DAS68 · 28th October 2013, 15:50

Just give me a bell if you need a hand Steve, I am around until Thursday morning then I go to Southampton until Sat/Sun

Brabus · 28th October 2013, 18:28

Hope you got it done with out to much hassle.

Godfer · 28th October 2013, 18:31

Quote:

Originally Posted by DAS68

Just give me a bell if you need a hand Steve, I am around until Thursday morning then I go to Southampton until Sat/Sun

That is what this Club is all about!

Best_of_British · 28th October 2013, 21:04

The problem

http://i828.photobucket.com/albums/z...ps0cf9660f.jpg

146000 and no history of clutch or slave change, car is still drivable with no hydralic leaks but with synergy on full and foot down the clutch is starting to slip.

The parts

http://i828.photobucket.com/albums/z...psb51f53a1.jpg

http://i828.photobucket.com/albums/z...ps3f24479e.jpg

http://i828.photobucket.com/albums/z...pscc3b363f.jpg

Engine cover and air intake off

http://i828.photobucket.com/albums/z...ps7c461723.jpg

Remove this to get access to top of box

http://i828.photobucket.com/albums/z...ps924bf4b5.jpg

FBH and mounting plate out of way

http://i828.photobucket.com/albums/z...psf08e8805.jpg

Space to work with Batery tray and UBP removed and moved out of way

http://i828.photobucket.com/albums/z...ps48e06a52.jpg

Slave to Master union undone

http://i828.photobucket.com/albums/z...pseb06fade.jpg

http://i828.photobucket.com/albums/z...psa708d8ed.jpg

With this, i found in old tool box

http://i828.photobucket.com/albums/z...psbc9a9bbd.jpg

If Slave has been replaced it was before 70000 miles and was replaced with original part

http://i828.photobucket.com/albums/z...ps42594198.jpg

I then removed the master cylinder through bulkhead which i found a pain awkward and finnished me off for the day.

So I made the car safe jacked up and well sprayed with penetrating oil for the hard graft tomorrow

http://i828.photobucket.com/albums/z...ps5e238ee3.jpg

http://i828.photobucket.com/albums/z...psbab88a98.jpg

Thanks Das68 for lending tools and offer to lend a hand, I may need it when box comes off.

Not a bad day and hopefully most of the prep work done ready for the hard part tomorrow.

Ross R75 · 28th October 2013, 21:36

Fixed for you:

Quote:

Originally Posted by Best_of_British

The problem

146000 and no history of clutch or slave change, car is still drivable with no hydralic leaks but with synergy on full and foot down the clutch is starting to slip.

The parts

Engine cover and air intake off

Remove this to get access to top of box

FBH and mounting plate out of way

Space to work with Batery tray and UBP removed and moved out of way

Slave to Master union undone

With this, i found in old tool box

If Slave has been replaced it was before 70000 miles and was replaced with original part

I then removed the master cylinder through bulkhead which i found a pain awkward and finnished me off for the day.

So I made the car safe jacked up and well sprayed with penetrating oil for the hard graft tomorrow

Thanks Das68 for lending tools and offer to lend a hand, I may need it when box comes off.

Not a bad day and hopefully most of the prep work done ready for the hard part tomorrow.

Best_of_British · 29th October 2013, 19:30

Thanks Ross R75 for the pictures, still getting the hang of it.

Started by fitting the Tazu Master Cylinder.

What a pig of a job, my neck and back took a battering in the footwell looking up. If you intend to tackle this yourself you will need bags of patience and a decent back.

The Tazu seems a decent product, but as was highlighted in Rich's howto I found the angle the pipe has to be bent to get it through the grommet into the plenum chamber very difficult. I was not happy bending the pipe to the extent I did to get it to fit, but see no other way.

Picture showing the Tazu in position
http://i828.photobucket.com/albums/z...ps614a6a2e.jpg

With grommet fitted
http://i828.photobucket.com/albums/z...ps75269c50.jpg

I found this very difficult to get it lined up with the bolt holes, and had to take a couple of breaks and come back to it, the grommet between the engine bay and plenum chamber was also very awkward to get at.

Once fitted I used this to fill it.
http://i828.photobucket.com/albums/z...psc2b0826d.jpg

Just pop the flexible spout in and press the trigger.

Picture showing copper pipe bent to roughly the correct position
http://i828.photobucket.com/albums/z...psef912ea2.jpg

Took 2 hours to get it fitted, but it was a stressful 2 hours.

I then tried to tackle the lower ball pinch bolts.
http://i828.photobucket.com/albums/z...ps192b3735.jpg

and they won 2-nill
http://i828.photobucket.com/albums/z...psea207074.jpg

Their still on the car and ive given up for today. It seems breaker bar and socket are not the correct approach, the nut came off easy but the bolt will not budge even after heat is applied and penetrating oil. If anyone could tell me the correct approach it will save the car from becoming an early bonfire.

I love how these cars are built but two things have tested my belief in Rover today, the diabolical design of the clutch master cylinder and the plastic retaining clips on the wheel arch liners, if anyone can get these all off in one piece

DAS68 · 29th October 2013, 19:39

Hit the pinch bolt with a large hammer and a decent flat blade srewdriver and it will shift it, dont worry about the threads as they are only on the very ends of the bolt and not all the way up. same happend to me, same advice given on here, job done in 5 mins.

Ross R75 · 29th October 2013, 19:52

Quote:

Originally Posted by Best_of_British

Thanks Ross R75 for the pictures, still getting the hang of it.

No problem, great work and good to see. And again:

Quote:

Originally Posted by Best_of_British

Started by fitting the Tazu Master Cylinder.

What a pig of a job, my neck and back took a battering in the footwell looking up. If you intend to tackle this yourself you will need bags of patience and a decent back.

The Tazu seems a decent product, but as was highlighted in Rich's howto I found the angle the pipe has to be bent to get it through the grommet into the plenum chamber very difficult. I was not happy bending the pipe to the extent I did to get it to fit, but see no other way.

Picture showing the Tazu in position

With grommet fitted

I found this very difficult to get it lined up with the bolt holes, and had to take a couple of breaks and come back to it, the grommet between the engine bay and plenum chamber was also very awkward to get at.

Once fitted I used this to fill it.

Just pop the flexible spout in and press the trigger.

Picture showing copper pipe bent to roughly the correct position

Took 2 hours to get it fitted, but it was a stressful 2 hours.

I then tried to tackle the lower ball pinch bolts.

and they won 2-nill

Their still on the car and ive given up for today. It seems breaker bar and socket are not the correct approach, the nut came off easy but the bolt will not budge even after heat is applied and penetrating oil. If anyone could tell me the correct approach it will save the car from becoming an early bonfire.

I love how these cars are built but two things have tested my belief in Rover today, the diabolical design of the clutch master cylinder and the plastic retaining clips on the wheel arch liners, if anyone can get these all off in one piece

Ross R75 · 29th October 2013, 19:56

Steve, it's easier to fill the master cylinder before you bolt it up in the pedal box. Give it a few pumps to pressurise it and then pop the valve at the end of the hose to release any trapped air. Connect to slave cylinder and job done.

Keep chipping away, brilliant to see people tackling this work.

27th October 2013, 17:03	#1
Best_of_British Gets stuck in Rover 75 Tourer & Arden Green Project Join Date: Jul 2012 Location: Ormskirk Posts: 932 Thanks: 159 Thanked 200 Times in 155 Posts	Clutch Day Tomorrow Well the day has come, tomorrow after my nightshift I will be starting clutch replacement, about the same time the worst storm for years hits our shores, sods law. I plan to replace clutch plate, pressure plate, CSC and fit new Tazu master cylinder and take a few photos in the process. Thanks to FrenchMike for his Howto and some good advice from DAS68 who has recently done his I feel confident enough to attempt it. Due to the inclement weather expected and the hours I will be awake. The first day will be taking it easy, I hope to get the car safe to work on clear space to work on the box from above by removing FBH, battery tray and starter motor. Underneath I will get the tray off and drop the gearbox oil and hopefully get the old master out and Tazu one in. On the Tazu I am going to stick with the copper supplied and see how it goes. I think that will be enough for a start and a good nights sleep will enable me to tackle the serious graft on Tuesday. I hope to complete it in 2 to 3 days but best laid plans and all that. I will take some photos of how I get on and post them on this thread.

28th October 2013, 15:50	#2
DAS68 Posted a thing or two 2001 75 CDT Moonstone Green,160 Remap, Hairpins, Half Leather Contemporaryand knob, ZT wheel. TAZU. Join Date: Aug 2011 Location: Burscough Lancashire (Scouser in Exile) Posts: 1,089 Thanks: 279 Thanked 79 Times in 50 Posts	Just give me a bell if you need a hand Steve, I am around until Thursday morning then I go to Southampton until Sat/Sun __________________ [SIGPIC][/SIGPIC] Improvise, Adapt and Overcome

28th October 2013, 18:28	#3
Brabus This is my second home 01 75 tourer cdt,1973 Rover 3500S,,1974 Rover 3500 Auto,1998 216 SE Coupe, 1968 Morris Minor 1000 Join Date: Jul 2010 Location: bangor/down Posts: 4,839 Thanks: 62 Thanked 184 Times in 158 Posts	Hope you got it done with out to much hassle. __________________ Regards Neale [SIGPIC][/SIGPIC] 121st 75 Tourer to be made 15th 75 Tourer CDT Club SE to be made 36th 75 Tourer in Zircon Silver Metallic to be made Membership No 903 I was one of the 541

28th October 2013, 21:04	#5
Best_of_British Gets stuck in Rover 75 Tourer & Arden Green Project Join Date: Jul 2012 Location: Ormskirk Posts: 932 Thanks: 159 Thanked 200 Times in 155 Posts	Update on day 1 The problem http://i828.photobucket.com/albums/z...ps0cf9660f.jpg 146000 and no history of clutch or slave change, car is still drivable with no hydralic leaks but with synergy on full and foot down the clutch is starting to slip. The parts http://i828.photobucket.com/albums/z...psb51f53a1.jpg http://i828.photobucket.com/albums/z...ps3f24479e.jpg http://i828.photobucket.com/albums/z...pscc3b363f.jpg Engine cover and air intake off http://i828.photobucket.com/albums/z...ps7c461723.jpg Remove this to get access to top of box http://i828.photobucket.com/albums/z...ps924bf4b5.jpg FBH and mounting plate out of way http://i828.photobucket.com/albums/z...psf08e8805.jpg Space to work with Batery tray and UBP removed and moved out of way http://i828.photobucket.com/albums/z...ps48e06a52.jpg Slave to Master union undone http://i828.photobucket.com/albums/z...pseb06fade.jpg http://i828.photobucket.com/albums/z...psa708d8ed.jpg With this, i found in old tool box http://i828.photobucket.com/albums/z...psbc9a9bbd.jpg If Slave has been replaced it was before 70000 miles and was replaced with original part http://i828.photobucket.com/albums/z...ps42594198.jpg I then removed the master cylinder through bulkhead which i found a pain awkward and finnished me off for the day. So I made the car safe jacked up and well sprayed with penetrating oil for the hard graft tomorrow http://i828.photobucket.com/albums/z...ps5e238ee3.jpg http://i828.photobucket.com/albums/z...psbab88a98.jpg Thanks Das68 for lending tools and offer to lend a hand, I may need it when box comes off. Not a bad day and hopefully most of the prep work done ready for the hard part tomorrow.

29th October 2013, 19:30	#7
Best_of_British Gets stuck in Rover 75 Tourer & Arden Green Project Join Date: Jul 2012 Location: Ormskirk Posts: 932 Thanks: 159 Thanked 200 Times in 155 Posts	Day 2 Thanks Ross R75 for the pictures, still getting the hang of it. Started by fitting the Tazu Master Cylinder. What a pig of a job, my neck and back took a battering in the footwell looking up. If you intend to tackle this yourself you will need bags of patience and a decent back. The Tazu seems a decent product, but as was highlighted in Rich's howto I found the angle the pipe has to be bent to get it through the grommet into the plenum chamber very difficult. I was not happy bending the pipe to the extent I did to get it to fit, but see no other way. Picture showing the Tazu in position http://i828.photobucket.com/albums/z...ps614a6a2e.jpg With grommet fitted http://i828.photobucket.com/albums/z...ps75269c50.jpg I found this very difficult to get it lined up with the bolt holes, and had to take a couple of breaks and come back to it, the grommet between the engine bay and plenum chamber was also very awkward to get at. Once fitted I used this to fill it. http://i828.photobucket.com/albums/z...psc2b0826d.jpg Just pop the flexible spout in and press the trigger. Picture showing copper pipe bent to roughly the correct position http://i828.photobucket.com/albums/z...psef912ea2.jpg Took 2 hours to get it fitted, but it was a stressful 2 hours. I then tried to tackle the lower ball pinch bolts. http://i828.photobucket.com/albums/z...ps192b3735.jpg and they won 2-nill http://i828.photobucket.com/albums/z...psea207074.jpg Their still on the car and ive given up for today. It seems breaker bar and socket are not the correct approach, the nut came off easy but the bolt will not budge even after heat is applied and penetrating oil. If anyone could tell me the correct approach it will save the car from becoming an early bonfire. I love how these cars are built but two things have tested my belief in Rover today, the diabolical design of the clutch master cylinder and the plastic retaining clips on the wheel arch liners, if anyone can get these all off in one piece

29th October 2013, 19:39	#8
DAS68 Posted a thing or two 2001 75 CDT Moonstone Green,160 Remap, Hairpins, Half Leather Contemporaryand knob, ZT wheel. TAZU. Join Date: Aug 2011 Location: Burscough Lancashire (Scouser in Exile) Posts: 1,089 Thanks: 279 Thanked 79 Times in 50 Posts	Hit the pinch bolt with a large hammer and a decent flat blade srewdriver and it will shift it, dont worry about the threads as they are only on the very ends of the bolt and not all the way up. same happend to me, same advice given on here, job done in 5 mins. __________________ [SIGPIC][/SIGPIC] Improvise, Adapt and Overcome

29th October 2013, 19:56	#10
Ross R75 Posted a thing or two Rover 75 Saloon Join Date: Apr 2007 Location: Edinburgh Posts: 1,535 Thanks: 137 Thanked 229 Times in 156 Posts	Steve, it's easier to fill the master cylinder before you bolt it up in the pedal box. Give it a few pumps to pressurise it and then pop the valve at the end of the hose to release any trapped air. Connect to slave cylinder and job done. Keep chipping away, brilliant to see people tackling this work. __________________ Copperleaf R75 CDT 160