mad1 Posted January 20, 2012 Report Share Posted January 20, 2012 Morning all As some of you might remember I am currently working on a 1984 2.25 110 I managed to free the clutch after it's been parked for so long ( 12+years!!) now what's happened is I pressed the clutch pedel in and it just "popped" I have no resistance at all it just feels like it's springing back with a spring ?? I have been reading different things and I am now aware that there is a weak spot in the link so I can get a new arm for £15 and have been told to reinforce it with a welded washer on it .. I have no prob tackling a job like this but I would like to know how much is involved ie does the engine have to come out or is there a easier way ?? Many thanks m1 Quote Link to comment Share on other sites More sharing options...
Alanl50 Posted January 20, 2012 Report Share Posted January 20, 2012 Id pop the seat box out and remove the gear box you might just have enough room to dress it back enough to do it without completely removing the box. Alan Quote Link to comment Share on other sites More sharing options...
stokie Posted January 20, 2012 Report Share Posted January 20, 2012 Engine doesn't need to come all the way out just enough to split the lump from the box . Although it would also be a good time to fetch it out and replace the crank case oil seal as they all leak eventually . Just my input as your going to have to do it eventually after endless tellings off about the oil on the drive ....... Lol Quote Link to comment Share on other sites More sharing options...
Dr_evil Posted January 20, 2012 Report Share Posted January 20, 2012 Put it up on ramps or over a pit, drop the box from engine, out with old clutch in with new one. Should be about 3 hours work Quote Link to comment Share on other sites More sharing options...
Paul223 Posted January 20, 2012 Report Share Posted January 20, 2012 buy the britpart arm they come ready reinforced, 3 hours to do auto data gives 6 for gearbox removal and refit Quote Link to comment Share on other sites More sharing options...
Paul223 Posted January 20, 2012 Report Share Posted January 20, 2012 you have checked the fluid level? more often than not when the arm goes the pedal goes hard / solid if the fluid is low could be a leaky cylinder Quote Link to comment Share on other sites More sharing options...
Luckyshot Posted January 20, 2012 Report Share Posted January 20, 2012 (edited) Morning all As some of you might remember I am currently working on a 1984 2.25 110 I managed to free the clutch after it's been parked for so long ( 12+years!!) now what's happened is I pressed the clutch pedel in and it just "popped" I have no resistance at all it just feels like it's springing back with a spring ?? I have been reading different things and I am now aware that there is a weak spot in the link so I can get a new arm for £15 and have been told to reinforce it with a welded washer on it .. I have no prob tackling a job like this but I would like to know how much is involved ie does the engine have to come out or is there a easier way ?? Many thanks m1 A very easy job but time consuming. This happened to my Defender a couple of years ago the rod the clutch arm pivots on pops through the middle of the arm rendering the clutch useless (my pedal went to the floor and went rock hard) I removed the gearbox tunnel inside the cab removed the gearbox cross member exhaust, clutch master cylinder, speedo drive, prop shafts, radiator (so you can tip the engine forward) etc and used an engine crane to lift gearbox/transfer box out in one lump dropping it onto the floor and then jacking the Defender up and dragging the box out the way. On your own you should be able to manage it in a day but you are non stop. I replaced the clutch at the same time aswell as a hd clutch fork (only difference is a metal plate welded over the weak spot. Worth doing yourself as a mate had his done and it cost him £300 just in labour alone. IFI had to do it again I think it would b just as quick to drop the motor out instead as its alot easier to work ontop rather than underneath. Yours will be slightly different as mine is a 300tdi. Put it up on ramps or over a pit, drop the box from engine, out with old clutch in with new one. Should be about 3 hours work You obviously havent done one then. Edited January 20, 2012 by Luckyshot Quote Link to comment Share on other sites More sharing options...
Dr_evil Posted January 20, 2012 Report Share Posted January 20, 2012 A very easy job but time consuming. This happened to my Defender a couple of years ago the rod the clutch arm pivots on pops through the middle of the arm rendering the clutch useless (my pedal went to the floor no resistance) I removed the gearbox tunnel inside the cab removed the gearbox cross member exhaust, clutch master cylinder, speedo drive, prop shafts, radiator (so you can tip the engine forward) etc and used an engine crane to lift gearbox/transfer box out in one lump dropping it onto the floor and then jacking the Defender up and dragging the box out the way. On your own you should be able to manage it in a day but you are non stop. I replaced the clutch at the same time aswell as a hd clutch fork (only difference is a metal plate welded over the weak spot. Worth doing yourself as a mate had his done and it cost him £300 just in labour alone. IFI had to do it again I think it would b just as quick to drop the motor out instead as its alot easier to work ontop rather than underneath. Yours will be slightly different as mine is a 300tdi. You obviously havent done one then. Done a series gearbox removal not a fender though Quote Link to comment Share on other sites More sharing options...
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