300TDI Disco clutch fork replacement
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1st Gear
Joined: Aug 2022
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300TDI Disco clutch fork replacement
Recently the clutch on my '98 disco 1 died. Took a look through the access hole for the slave cylinder with a boroscope and saw the dreaded pivot ball poking through a fresh hole in the clutch fork.
I did a bit of research and found that Britrest seems to have the best solution to this weak spot. Rather than just welding a plate on the back like most 'heavy duty' aftermarket forks, they have put in a nylon bushing in place to eliminate the friction that causes failure, so I've ordered one to replace mine:
https://britrest.com/product/super-duty-clutch-fork/
As I understand this is a gearbox-out job so I have two questions for the community.
Firstly, what maintenances items should I tackle while I have the gearbox out? Previous owner has neglected maintenance and there are a few oil leaks. Rear main seal comes to mind, is there anything else that is advisable such as shifter linkage bushings or various seals and o-rings? The clutch itself seems to grip well so I'm not sure if I can justify replacing it entirely but I'm willing to consider it if it's one of those "might as well" situations. Other things I've read on other threads are:
Secondly, what is the most painless way to do this job? I've read other threads that say taking the engine out is an option but the consensus seems to be that dropping the gearbox is the easier way. I have a transmission jack, but it's a low profile one with a max height of 680mm. I've seen in some threads that it is advisable to build a custom bracket to bolt onto the gearbox and while I do have access to a welder and a drill press, I don't have much experience with fabrication.
I did a bit of research and found that Britrest seems to have the best solution to this weak spot. Rather than just welding a plate on the back like most 'heavy duty' aftermarket forks, they have put in a nylon bushing in place to eliminate the friction that causes failure, so I've ordered one to replace mine:
https://britrest.com/product/super-duty-clutch-fork/
As I understand this is a gearbox-out job so I have two questions for the community.
Firstly, what maintenances items should I tackle while I have the gearbox out? Previous owner has neglected maintenance and there are a few oil leaks. Rear main seal comes to mind, is there anything else that is advisable such as shifter linkage bushings or various seals and o-rings? The clutch itself seems to grip well so I'm not sure if I can justify replacing it entirely but I'm willing to consider it if it's one of those "might as well" situations. Other things I've read on other threads are:
- Spigot Bearing
- Thrust Bearing
- Vacuum Pump Gasket
- O-rings for oil cooler pipes
- Oil Thermostat o-ring
- P/S feed hose to pump
- Rocker Cover Gasket and Sealing Washers
Secondly, what is the most painless way to do this job? I've read other threads that say taking the engine out is an option but the consensus seems to be that dropping the gearbox is the easier way. I have a transmission jack, but it's a low profile one with a max height of 680mm. I've seen in some threads that it is advisable to build a custom bracket to bolt onto the gearbox and while I do have access to a welder and a drill press, I don't have much experience with fabrication.
Three Wheeling
Joined: Oct 2009
Posts: 90
Likes: 32
From: Pittsburgh, PA, USA
I just replaced the clutch in my D1 200TDI. I wish I would've seen the HD bushing from Brit-Rest. I would've done the DIY upgrade. Since yours is just the clutch arm. I would replace just the arm but check everything while the trans is out.
My clutch was slipping and worn out. So I replaced it with a clutch kit, HD arm kit and all the parts inside the bellhousing.
I cleaned up all the shifter components and transfer case shifter. Put fresh coat of grease on everything.
Pulling the trans is a big job. Take your time! I used an engine hoist (cherry picker) thru the trans tunnel to reinstall the trans. Made it super easy to put the bolts back in and guide the trans back in. Taking it out and lower it to the ground isn't too bad. Getting it back in is the major pain in the butt!! Check out the Haynes Manual for some good pointers.
Good luck!
My clutch was slipping and worn out. So I replaced it with a clutch kit, HD arm kit and all the parts inside the bellhousing.
I cleaned up all the shifter components and transfer case shifter. Put fresh coat of grease on everything.
Pulling the trans is a big job. Take your time! I used an engine hoist (cherry picker) thru the trans tunnel to reinstall the trans. Made it super easy to put the bolts back in and guide the trans back in. Taking it out and lower it to the ground isn't too bad. Getting it back in is the major pain in the butt!! Check out the Haynes Manual for some good pointers.
Good luck!
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