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Author Topic: Clutch replacement thread/link  (Read 348 times)

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Clutch replacement thread/link
« on: February 26, 2020, 02:44:15 PM »
Hello all. If there is one available, could somebody send a link to a thread for clutch replacement?...I have searched using the search button, but didn't see anything obvious. Thanks in advance.

Offline Jakehands

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  • Posts: 108
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 04 1.9tddi 130ps
  • First Name: Jake
  • Region: West Midlands
Re: Clutch replacement thread/link
« Reply #1 on: February 26, 2020, 07:10:59 PM »
What do you need to know? Ive done mine on the 1.9tdi 6speed

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #2 on: February 26, 2020, 07:32:50 PM »
Hi there. I'm looking for hopefully step by step procedure with things to look out for,... a bit like insanitybeards procedure for a cambelt change (link below, which was excellent! )
Cheers.


https://www.fordmpv.com/smf2/ford-galaxy-common-faults-and-problems/ford-galaxy-mk2-1-9-tdi-(pd)-timing-belt-kit-water-pump-replacement/

Offline johnnyroper

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  • Posts: 2789
  • Thanked: 134
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #3 on: February 26, 2020, 08:22:16 PM »
Not seen a guide but whenever I do them I just have a good look around the engine bay and underneath and find they are usually fairly self explanatory.

I suspect you could leave the subframe in place and slide box off and rest on the frame,it may need that side of frame dropping slightly.
I have done a few different cars that way lately. Tip for aligning when doing it that way as space is limited is 2 very small dabs of superglue on friction plate and put it on pressure plate centrally. Done 3 like that and box went straight on.

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #4 on: February 26, 2020, 09:52:03 PM »
Wow that sounds ingenious. Do you mean dabs of glue instead of using clutch aligning tool? Also there is the dual mass flywheel to renew isn't there when you do the clutch? The clutch is ok at mo, but it's a job I would like to have a go at one day. My clutch pedal is quite stiff, and plays havoc with my sciatica, I'm thinking a new clutch would free up clutch pedal pressure a bit...

Offline johnnyroper

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  • Posts: 2789
  • Thanked: 134
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #5 on: February 26, 2020, 11:23:01 PM »
Yes thatís it as you canít quite get alignment tool in with box pushed back,although to be fair even when I have box out I donít use alignment tool I usually do it by eye.

I would always renew DMF at same time unless you know the DMF has been changed recently.
If you do it some clutch spline grease on clean splines,pivot point clean and lube along with a good bleed might help free it up a bit.

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #6 on: February 26, 2020, 11:43:39 PM »
Ok thanks for tips. Next time you do one of these tdi clutches, it would be worth you filming it with your tips, and wacking on YouTube! No one from what I can find has done a decent clutch removal vid yet, and some of those vids get 1000's of views....thanks again

Offline Jakehands

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  • Posts: 108
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 04 1.9tddi 130ps
  • First Name: Jake
  • Region: West Midlands
Re: Clutch replacement thread/link
« Reply #7 on: February 27, 2020, 08:06:07 AM »
I took off battery tray then links,hydralic cable, lifted the car up dropped the driveshafts (and mount behind the engine for DS) then propped the engine and roped the box (no gearbox hoist) removed the starter motor undone the gearbox bolts then a few wiggles took the whole box off lowered it with the rope then had complete access to the clutch. Was a pain getting it back on (4 scissors jacks) just make sure you change the slave and bleed it properly. 5mm drill bit works nicely to home the gears back :)

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #8 on: February 27, 2020, 12:33:54 PM »
Thanks for info, you make it sound easy (I bet it's not). How long did it take just out of interest,  and did you come across any 'odd' tools that you need? Cheers

Offline Jakehands

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  • Posts: 108
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 04 1.9tddi 130ps
  • First Name: Jake
  • Region: West Midlands
Re: Clutch replacement thread/link
« Reply #9 on: February 27, 2020, 01:58:36 PM »
2 days and a few beers (i have 4 kids so finding time waa difficult) id say with a hoist about 5-6 hours depending on experience. Buy the allignment tool as its just easier. I belive the bolts are the 12 sided star (unsure on name) i have the tool for it. Found a few rounded ones which was a pain. Oddest tool 5mm drill bit lol it is a tight job getting it out. Bleeding is the annoying part. Buy a slave cylinder and replace that aswell. Plenty of geabox oil and dot4

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #10 on: February 27, 2020, 02:59:35 PM »
Ok cheers. Yes time is the problem I have, kids etc. Its ok if you got another car to use when it's off road, luxury then,  but more often than not  I havn't got another car. Thanks again

Offline brianh

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  • Posts: 722
  • Thanked: 67
  • Model: Galaxy Mk2
  • Spec: 2001 2.3 Ghia LPG
  • First Name: Brian
  • Region: South East
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #11 on: February 27, 2020, 10:46:08 PM »
The Clutch on the petrol 2.0 was easy to change by comparison of the mk2 mondeo I had which we changed the clutch on. That was a pig to do as the subframe needed to come off, which would have been fine if the bolts weren't rusted solid so as soon as you try to remove them the captive nuts became not so captive anymore, and span round where you couldn't get to them.

Engine crane did help a lot though. Space and time to do it helps a lot too along with someone to give you a hand with it.

Offline MrBen

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  • Posts: 38
  • Thanked: 0
  • Model: Alhambra Mk2
  • Spec: 2004 tdi
  • Region: South West
  • Country: United Kingdom
Re: Clutch replacement thread/link
« Reply #12 on: February 27, 2020, 10:53:29 PM »
Yes 4 hands better than two! Cheers.

 

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