The Dispatch | Expert | Scudo Hub

ckcarpvan

Member

Registered: 2021-02-06

Posts: 11

Clutch replacement.

Hello again, was wondering if anyone could give me a general idea of how long a driveway clutch and flywheel replacement would take? I know my way around an engine bay, just haven't done this job before.

JohnDragonMan

Member

From: Derby, East Midlands, UK

Registered: 2020-06-02

Posts: 402

Website

Re: Clutch replacement.

its not a fun job. i did it on my HDI but it involves a complete front end removal with radiators, gearbox that wont fit through gaps, a sub frame that wont unbolt because the captive nuts break away, ABS pump that needs to be removed.. then you have all the things you have to take off.. take it from me its not a job i would want to do again.

take it to a place that repairs taxis... they know all the tricks and are usually cheap. dont forget to replace the crank shaft oil seal too
on the HDI the crank shaft oil seal size is : 90-7-110 with a Left-hand twist.

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- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: Internally rust proof the sills and subframe! both skins!!. There's always user serviceable parts inside. "Oh that shouldn't have happened".
My 2005 Dispatch Camper Project

mralex666

Member

Registered: 2021-02-02

Posts: 1

Re: Clutch replacement.

Hi Ckcarpvan,
It can be done without too much hassle, I replaced my clutch and swapped out to a solid flywheel by just sliding gearbox over and resting on subframe giving enough room to do the replacement without having to tackle the dreaded subframe bolts, abs pump etc etc
I used this video as a guide, Youtube
only difference was extra hoses for the turbo / intercooler, and disconnecting anti roll bar ( if you have one) for ball joint seperation.
as long as you have alll tools necessary, should be doable in a day/ afternoon.
And as JohndragonMan said, if you can, do the crank seal whilst you are in there

ckcarpvan

Member

Registered: 2021-02-06

Posts: 11

Re: Clutch replacement.

cheers for your help, the subframe will need to come off at some point its in a fairly sorry state, but I have had a word with a mate of mine who is handy with the spanners also, so I think I will box off the clutch sooner rather than later, then get his help with the subframe, top mounts, track rod ends and god knows what else i find along the way

ckcarpvan

Member

Registered: 2021-02-06

Posts: 11

Re: Clutch replacement.

Started clutch replacement today, got it all stripoed down and old clutch out, turns out it has already had a solid flywheel fitted at some point. Next job rebuild it all.

ckcarpvan

Member

Registered: 2021-02-06

Posts: 11

Re: Clutch replacement.

Latest update - Gearbox is now back in, allbeit a huge ballache to do by myself, next job is to replace the crank sensor as i appear to have smashed it, not sure if flywheel slightly different dimension or whether I broke it whilst locating the gearbox.