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Christian1402



Member Since: 17 Feb 2016
Location: Cumbria
Posts: 214

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Indus Silver
Td5 clutch change. Engine or box out?
Hi guys,

The clutch has started slipping on my 90 and I refuse to pay a garage to replace it. I’m weighing up my options (will be doing it on my own or with one friend helping once lockdown eases)

I’m thinking it’ll be easier to lift the engine out rather than drop the gearbox down underneath. I was wondering weather anyone has done a clutch change on their drive before, and which option you chose and why.

I have an engine crane, and just don’t fancy struggling to lift The gearbox and transfer box about underneath the car.

Thanks
Christian.
Post #830602 12th May 2020 7:26am
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Harry.O



Member Since: 25 Jul 2014
Location: Warwickshire
Posts: 704

United Kingdom 1989 Defender 90 300 Tdi ST Nato Green
Gearbox out, it's also a bit cleaner since you aren't messing about disconnecting coolant and PAS pipes etc. My gearbox failed whilst on holiday in Ireland and I dropped the gearbox with a bottle jack, a trolley jack and a borrowed socket set in the corner of someone's farmyard, it wasn't ideal but easily doable single-handed.

If you have an engine crane then it would be even easier, take out the seatbox lid and put the crane in through the door to lower the gearbox onto the floor, a bottle jack under the crank pulley helps to tip the engine back. You may then need to jack up the vehicle to get the gearbox out from underneath as the bellhousing might not fit under the chassis rails (assuming you have height standard suspension). 2005 Td5 110 Hardtop
1989 300Tdi 90 Soft top
1992 200Tdi 90 Truck cab with Land Cruiser axles
Post #830604 12th May 2020 7:40am
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Christian1402



Member Since: 17 Feb 2016
Location: Cumbria
Posts: 214

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Indus Silver
I see what you’re saying re the coolant and pas, I’m not too fussed about making a mess it’s more just the struggle of getting things out/back in.

The crane through the door could work though, that’s a good shout. I don’t Necessarily need to get the gearbox out from under the car, providing I have enough room to whip the clutch and flywheel off.

I just envision getting the gearbox out ok and not being about to get it back up and into position on my own, I only have a trolley jack, I haven’t yet invested in a bottle jack and my defender doesn’t have one!
Post #830612 12th May 2020 8:34am
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Mo Murphy



Member Since: 01 Jun 2008
Location: Letchworth Garden City, Herts
Posts: 2062

United Kingdom 1984 Defender 90 200 Tdi HT Pennine Grey
If the vehicle is on the ground then engine out, it's much easier and more accessible.
These days I have access to a 4 poster and it's easier then to do gearbox and transfer box out with the vehicle up in the air.
Thus

Click image to enlarge


HTH
Mo The Land Rover 90 - Many are called, few are chosen.
Post #830638 12th May 2020 9:38am
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Nidge



Member Since: 27 Jan 2008
Location: Kildare Ireland
Posts: 809

Ireland 2009 Defender 110 Puma 2.4 HCPU Cairns Blue
Just replaced the clutch on mine and agree with Mo, engine out if you have a crane and box out if you have a lift but it really depends on the equipment you have access to.

I'd also look to change flywheel and rear crank seal while you are at it and if changing the crank seal a new sump seal as you need to drop sump slightly on TD5 to do crank seal properly.

Snap Mo Thumbs Up

Click image to enlarge
Post #830678 12th May 2020 12:09pm
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Mo Murphy



Member Since: 01 Jun 2008
Location: Letchworth Garden City, Herts
Posts: 2062

United Kingdom 1984 Defender 90 200 Tdi HT Pennine Grey
Thumbs Up snap indeed nidge !
Mo The Land Rover 90 - Many are called, few are chosen.
Post #830697 12th May 2020 2:44pm
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Christian1402



Member Since: 17 Feb 2016
Location: Cumbria
Posts: 214

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Indus Silver
Well that’s that then! Looks like I’ll be taking the engine out. This will get the neighbours talking 😅

Thanks for the advice Thumbs Up
Post #830812 13th May 2020 7:13am
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6026

United Kingdom 2006 Defender 110 Td5 SW Epsom Green
I did mine last year on the drive with engine crane. I dropped the gearbox down (for the same reasons mentioned; couldn't be arsed with the mess of the coolant and fuel pipes), plus my gearbox is mounted on a 300Tdi crossmember so it's removable, makes the gearbox "easier" (as in, slightly more easier than wrestling a bear) to get the 'box out.

I also had to hi-lift one side of the 110 up to allow the box to slide out from underneath (I dropped it onto a large steel drip tray, made it slightly easier to slide across the tarmac)
Post #831004 14th May 2020 8:00am
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roel



Member Since: 08 Aug 2009
Location: Lelystad
Posts: 2039

Netherlands 2003 Defender 90 Td5 PU Caledonian Blue
I also would go with the gearbox out. Till now I didn't take the gearbox out yet only the transfer box off. But with a rollcage and some ratchet straps it was easy. Roel

1984 90 2.5 na Diesel - RR V8 (1994-2001)
1997 Camel Trophy Discovery 300TDI (2001-2009)
2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts.
2003 90 Td5 (2009-now)
Post #831124 14th May 2020 8:34pm
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
Having done engine out and gearbox out, I'd choose to do the gearbox route personally. Easier with 2, possible with 1 and a trolley jack. High lift trolley jack and jack adapters are on my list for next time!
Post #831131 14th May 2020 9:20pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16809

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
^^ If the high lift trolley jack is primarily for doing this job, you might want to consider a bespoke transmission jack. It is much more stable, and really does make the job easier.

This is the sort of thing I mean (chosen at random for illustrative purposes):

https://www.lawson-his.co.uk/sealey-500cew...ya-p119997
Post #831168 15th May 2020 7:11am
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6026

United Kingdom 2006 Defender 110 Td5 SW Epsom Green
And my rear crank seal is now pssing out.... so looks like it'll be engine or box out again Rolling Eyes Banging Head
Post #831209 15th May 2020 11:27am
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