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Old 17th January 2017, 19:26   #1
EastPete
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Default Clutch change saga

After three years of trying to get local garages and assorted 'expert mechanics' to get me a decent clutch in my 75 CDTi, I am biting the bullet and changing the clutch myself. I have the Tazu Mk1 master in my car, which seems fine and I will leave in place. I have ongoing issues with a grinding/whirring noise (probably release bearing related) when I change gear, with some judder. The car currently has a National clutch kit in it fitted by a former trader on this forum. I am going to fit a Borg and Beck kit with a metal slave cylinder (currently on its way from DMGRS). I am going to do the job by the book - subframe off etc. and I am going to take my time doing it, to try to get everything spot on. I'll post updates in this thread, to act as a guide to members thinking of tackling the job themselves, and also to ask for advice where needed, as I go along.

I started today by jacking the car up nice and high and firmly supporting it on axle stands under the sills. I removed the undertray and n/s wheel arch liner. I cracked the bottom drop link/ARB joint and the lower arm/hub pinch joint. I then drained the gearbox oil (strange finding No. 1: 2 litres came out - I thought these boxes only held 1.6 litres).

I'll crack on as and when time/energy allows. I envisage spreading the job over the next 2-3 weeks, in between work and family commitments.

Wish me luck - it is bit scary doing this for the first time !

Cheers

Pete
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Old 17th January 2017, 19:35   #2
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Best wishes
Sure if you take your time it should work out fine
And as they say pratice makes perfect and their will be alot of use ouf there to let you pratice on
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Old 17th January 2017, 19:41   #3
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Cool, all the best with it. I thought you had the metal slave fitted already, as I have. I think mine has been in nearly 12 mths now without issue. The jury is still out whether the metal slave is best or not. I won't go back to plastic again whatever. They seemed to be ok originally but maybe corners have been cut with todays replacements. Anyways, the gearbox is well heavy so take it steady eh?
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Old 17th January 2017, 19:43   #4
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Hello Pete, thanks for the order - it should be with you shortly.
The Metal Slave in my opinion is the best way forward, hopefully your experience is shared with the other members who have one too.

Good luck with the work, especially in the awful drizzly weather we've had recently.
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Old 17th January 2017, 19:49   #5
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Quote:
Originally Posted by Heddy View Post
Cool, all the best with it. I thought you had the metal slave fitted already, as I have. I think mine has been in nearly 12 mths now without issue. The jury is still out whether the metal slave is best or not. I won't go back to plastic again whatever. They seemed to be ok originally but maybe corners have been cut with todays replacements. Anyways, the gearbox is well heavy so take it steady eh?
I have had a metal slave in there for about a year - I considered leaving it in and just changing the pressure/driven plate, but since the noise sounds release bearing related, I do not want to take any chances re-using the current slave, so I have ordered a new one. I do not think there is an issue with the slave itself - I think my issues may be down to the quality of the clutch kit that is currently in there (National), plus less than optimal fitting techniques used by previous mechanics that have worked on the clutch.

I have an engine crane that I will use to remove/refit the gearbox, so that should make life easier.

Cheers

Pete
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Old 17th January 2017, 20:46   #6
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PETE.

Don't forget French Mikes How-To on here. Could be very useful to you.

Any extra pics though could be handy.---
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Old 17th January 2017, 20:58   #7
EastPete
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Originally Posted by COLVERT View Post
PETE.

Don't forget French Mikes How-To on here. Could be very useful to you.

Any extra pics though could be handy.---
Thanks - I have seen Mike's how-to. I am actually going to follow the more laborious method of dropping the subframe and completely removing the gearbox. That way, you can clean everything up and make sure it all goes back together without (hopefully) damaging anything in the process. Time will tell !

Cheers

Pete
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Old 17th January 2017, 21:46   #8
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Wow.. Well done. I hope you've got someone on standby making plenty of cuppa's
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Old 17th January 2017, 22:18   #9
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Pete, when I did mine I started with Frenchmikes approach. But I just couldn't get with the twisting motion required to clear the sub frame. I ended up dropping the subframe.

However, what I did find invaluable from Mikes how to was the self made tool that sits on the gearbox mount.

I found when using this this gave me the oppotunity to tie off, rest and move / reposition the jack or whatever with the box still suspended. If you are doing this on your tod then its a bit like having another set of hands.

I must admit, I struggled with this but if I have to do this again I would definitely go with the drop subframe way. Hard but very satisfying - so much so that I would do the clutch again. Unlike the struts/springs. Never, ever, ever again! Really did not like the compression!

Good Luck!
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Old 17th January 2017, 23:05   #10
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Quote:
Originally Posted by EastPete View Post
After three years of trying to get local garages and assorted 'expert mechanics' to get me a decent clutch in my 75 CDTi, I am biting the bullet and changing the clutch myself. I have the Tazu Mk1 master in my car, which seems fine and I will leave in place. I have ongoing issues with a grinding/whirring noise (probably release bearing related) when I change gear, with some judder. The car currently has a National clutch kit in it fitted by a former trader on this forum. I am going to fit a Borg and Beck kit with a metal slave cylinder (currently on its way from DMGRS). I am going to do the job by the book - subframe off etc. and I am going to take my time doing it, to try to get everything spot on. I'll post updates in this thread, to act as a guide to members thinking of tackling the job themselves, and also to ask for advice where needed, as I go along.

I started today by jacking the car up nice and high and firmly supporting it on axle stands under the sills. I removed the undertray and n/s wheel arch liner. I cracked the bottom drop link/ARB joint and the lower arm/hub pinch joint. I then drained the gearbox oil (strange finding No. 1: 2 litres came out - I thought these boxes only held 1.6 litres).

I'll crack on as and when time/energy allows. I envisage spreading the job over the next 2-3 weeks, in between work and family commitments.

Wish me luck - it is bit scary doing this for the first time !

Cheers

Pete

Dont forget the guide tube UTL100080
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