Clutch change gti 8v

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rutter123
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Clutch change gti 8v

Post by rutter123 » Mon Mar 31, 2014 4:45 pm

Not done a petrol before, done a few diesels, are they much the same to do? do i need to completely remove the o/s driveshaft or leave in situ drawing the gearbox from the shaft? i will be removing the rad makes acces around the fdv easier. Any tips to make life a little easier? is it this type where the thrust bearing has a nasty habit of falling off during re-assembly?
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JayW
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Re: Clutch change gti 8v

Post by JayW » Mon Mar 31, 2014 8:07 pm

I really is pretty much the same. The bearing will depend which of the 2 fork arrangements you have, but if you fit it then use cable ties to tie the arm into position it'll stay on.

Even if you do magically manage to do it with the shaft in place it's gonna be more of a ballache than you can possibly imagine! I usually unbolt the intermediate bearing and bottom balljoint and withdraw them still attached to the hubs.

Doing mine tommorow funnily enough!
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David
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Re: Clutch change gti 8v

Post by David » Mon Mar 31, 2014 11:14 pm

The only advise I can give is to remove the RH drive shaft, Otherwise you will be struggling for hours & risk the possibility of damaging the oil seal. If you remove the radiator & all the air pipes you will be able to see what you are doing & hopefully get it done a little easier. For what little time it takes to remove them will be worth it when your attempting to reassemble it.

Good luck & let us know how you get on.
1992 Citroën BX 1.9 Diesel Meteor 4x4 - The Project.

1992 Citroën BX 1.9 TXD (with GTI engine; Mulleys old car) - Parts car.

2004 Citroën Xsara Desire. (Now gone).

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Re: Clutch change gti 8v

Post by rutter123 » Tue Apr 01, 2014 10:54 am

can i remove the bottom ball joint with the drop links still attached both ends?
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JayW
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Re: Clutch change gti 8v

Post by JayW » Tue Apr 01, 2014 6:25 pm

Yes.

Provided the system is depressurised you'll be able to lift the hubs clear out of the arms by hand once you've broken the initial grip of the balljoints.

Did my clutch and gbox swap today, started at 9:30, finished at 14:30 with a break for lunch, including swapping the clutch fork over. The only thing stopping me driving away was having forgotten to take the new clutch cable with me #-o

Good luck!
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Re: Clutch change gti 8v

Post by rutter123 » Tue Apr 01, 2014 6:57 pm

Just about managed to limp it the 11 miles home today, be a job for the weekend i guess. remove top engine mount?
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Re: Clutch change gti 8v

Post by JayW » Tue Apr 01, 2014 9:12 pm

Not necessary, just the one on the 'box (obviously).

Once you've lowered the engine/box a bit with the trolley jack, completely remove the gearbox mounting stud and it'll make life a lot easier when it comes to space-to-move.
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Re: Clutch change gti 8v

Post by rutter123 » Thu Apr 03, 2014 12:20 pm

i was not aware that the gearbox mounting stud could be removed, i always thought it was pressed into the casing, i remember having trouble getting the tzd box back in with that stud getting in the way, how to remove it?
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Re: Clutch change gti 8v

Post by JayW » Thu Apr 03, 2014 4:29 pm

Unwind it, it's just a bolt!

You can use a spanner, but parrot-nose pliers if you have them speed things up a lot!
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Re: Clutch change gti 8v

Post by David » Thu Apr 03, 2014 4:33 pm

Its just a 16mm (I think) bolt. Get a long socket on it & undo it. It will make things a lot easier. You can normally get at it with the mounting removed through the battery box.
1992 Citroën BX 1.9 Diesel Meteor 4x4 - The Project.

1992 Citroën BX 1.9 TXD (with GTI engine; Mulleys old car) - Parts car.

2004 Citroën Xsara Desire. (Now gone).

2011 Ford Focus Zetec - Daily Driver. (Absolute bone shaker).

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Re: Clutch change gti 8v

Post by rutter123 » Thu Apr 03, 2014 6:28 pm

I seem to remember about an hour long battle getting the box back in the tzd, i'm removing the rad anyway as i have a new one to fit and for the sake of a few quid will replace the outer c/v gators whilst its all apart as they looking a bit aged. Will have a go at removing the stud to save a bit of time.
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability

rutter123
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Re: Clutch change gti 8v

Post by rutter123 » Sat Apr 05, 2014 6:58 pm

job done, no real probs apart from getting the mounting stud out of the gearbox (that was real tight), took about 6 hours including several tea stops from start to finish, so much better now. i'd guess it was the pressure plate that was knackered as the friction plate didnt seem that bad.
Attachments
004.jpg
gearbox out
005.jpg
the offending items
003.jpg
new clutch in place
90 BX Tzd turbo 294k SORN undergoing major surgery
90 BX Tzd turbo estate 46k awaiting surgery
65 Peugeot Boxer Van the new workhorse
52 Toyota Rav4 180k Bulletproof Jap reliability