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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5506

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey
DIY Clutch Change - What Top Tips?

Hello all,

I shall soon be undertaking a clutch and output shaft change. I have access to a full size lift and a guy who’s maintained, fixed, recovered etc trucks and HD vehicles most of his life. But can someone please confirm what items I’ll need to think about, any top tips, and cheeky little shortcuts etc.

I’ll be fitting a Clutchfix HD Clutch and Ashcroft output shaft.

For the clutch, which of these tools do I need?

https://www.rld-autos.com/fr/outillage/176...;results=1

https://www.rld-autos.com/fr/outillage/178...;results=1

Also I changed both Trans and Gearbox fluids a month ago, can I keep them if I filter them? And what clutch fluid is recommended?

And for the output shaft, there’s some kind of clamp thingy I need. Anyone know what it’s called, where I can find one and whether it is definitely needed ? Think I might be able to borrow one if so.

Thanks a always. Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #929816 15th Nov 2021 12:49pm
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 611

United Kingdom 

On the oil front, no I would not drain, filter and reuse. In the scheme of things the cost of fresh oil is marginal, so why risk it when you are spending good monies on quality new components and their fitting.
In fact if not already fitted I would add quality magnetic drain plugs to the list.

Post #929820 15th Nov 2021 1:13pm
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Race.it



Member Since: 27 Aug 2019
Location: Algeciras
Posts: 519

Spain 2010 Defender 110 Puma 2.4 SW Alaska White

Is there a part number for the drain plugs or maybe a supplier? Next time I change mine I want to put them in.

On the clutch from what I read, not done it you may need a few extensions to get to the top bolts on the gearbox to engine.

Also take out the transfer case seperate to the gearbox. Searching for my first Defender...and started just as Covid hit, so talk about timing.

5 months after starting the search I found it, and here is the details.

Post #929837 15th Nov 2021 2:45pm
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 611

United Kingdom 

magnetic drain plugs for gear box etc https://www.megasquirt-v8.co.uk/diff_offroad.php

Also https://foundry4x4.co.uk/index.php?route=p...th=65_1758

AS I understand it the gearbox has internal magnets, but I added a magnetic one as the drain. A belts and braces approach which can’t hurt, plus it had a hex head.

The transfer drain should already be a magnetic plug.

Diffs benefit from drain and fill magnetic plugs as they are level fill.

Back to original post, a impact wrench will help remove the bolt securing the output shaft cup to the gearbox. A strong puller , some recommend an hydraulic puller, will help remove the cup off the splines. I expect your helper will have those though.

These may help

https://www.youtube.com/watch?v=dPFUyCVNQGE

https://www.youtube.com/watch?v=R4JjSv3NKbg

https://www.youtube.com/watch?v=kAFmt_PsYfs

Also Nigel’s (Nige - Gloucesternige on here ) landrover channel has some great videos on the gearbox

https://youtube.com/c/Defender90KeswickNigelsLandRoverchannel

Post #929882 15th Nov 2021 7:38pm
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5506

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

Thank you all. Makes sense on the fluids, so have ordered some fresh stuff. And I’ll look through all the videos Ian, thanks for the links.

Here’s a photo of the beast being recovered with help from a friend. Thumbs Up



Click image to enlarge
 Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #930063 17th Nov 2021 8:05am
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Leamreject



Member Since: 19 Dec 2020
Location: Middle Earth - Leamington Spa
Posts: 466

Italy 2011 Defender 90 Puma 2.4 HT Fuji White

Now that is an envious picture… two beauties Bow down Ride like you stole it!!

Post #930064 17th Nov 2021 8:07am
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5506

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

This is a good video as well. Thumbs Up

 Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #930065 17th Nov 2021 8:07am
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 611

United Kingdom 

Grenadier wrote:
Thank you all. Makes sense on the fluids, so have ordered some fresh stuff. And I’ll look through all the videos Ian, thanks for the links.

Here’s a photo of the beast being recovered with help from a friend. Thumbs Up



Click image to enlarge


Colour and wheel base coordinated recovery, with both trucks polished and gleaming. Now that’s recovery with a touch of french flair Very Happy
.
.

Post #930091 17th Nov 2021 1:02pm
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5506

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

Too kind.

How much Dot 4 do I need for the master and lines? Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #930094 17th Nov 2021 1:25pm
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DeeEss



Member Since: 30 Apr 2015
Location: Zürich / Oslo
Posts: 297

Norway 2015 Defender 110 Puma 2.2 SW Corris Grey

not much. if you buy 500ml you'll have plenty left over. Get an old fashioned oil can and reverse bleed it. Roaming around 🇳🇴🇨🇭

Post #930100 17th Nov 2021 1:58pm
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piechipsandpeas



Member Since: 12 May 2021
Location: Albany, Western Australia
Posts: 59

Australia 2013 Defender 110 Puma 2.2 SW Indus Silver

Another way to undo the adaptor shaft cup bolt off the gearbox output shaft is to stop the cup rotating with a piece of wood cut to length and fit a suitable sized bolt through at one end that rests in one of the cut-outs on the cup, with the other end resting on the floor of the workshop. Then undo the bolt on the end of the output shaft with a socket suitable sized bar through the hole in the transmission tunnel with the cover under the cubby box removed.



Click image to enlarge


Cup is then removed using a suitable puller.

Post #930208 18th Nov 2021 11:21am
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 5506

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

Well, it’s done. Some action shots. It was an OS failure, not the clutch, but that was well gone anyway.



Click image to enlarge



Click image to enlarge



Click image to enlarge



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Click image to enlarge
 Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #930653 22nd Nov 2021 7:52am
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Co1



Member Since: 19 Aug 2018
Location: North Yorkshire
Posts: 2556

United Kingdom 2013 Defender 90 Puma 2.2 HT Loire Blue

Nice work! Instagram @richmond_custom

Post #930725 22nd Nov 2021 6:53pm
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DeeEss



Member Since: 30 Apr 2015
Location: Zürich / Oslo
Posts: 297

Norway 2015 Defender 110 Puma 2.2 SW Corris Grey

Good job David Thumbs Up Roaming around 🇳🇴🇨🇭

Post #930726 22nd Nov 2021 7:02pm
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 5355

United Kingdom 2006 Defender 110 Td5 SW Epsom Green

I still can't believe how LR get away with this shoddy design (or indeed deny there's any issue)

Post #930731 22nd Nov 2021 7:08pm
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