How do you change a clutch express L300?

Answer 1

Jack up vehicle and place 4 stands front and back so you can easily roll in and out of under the car. Disconnect battery.

1. Remove tailshaft (4 bolts) at the rear uni joint.

2.Remove speedo cable and disconnect reverse light wires and earth straps attached to gearbox. Disconnect clutch cable and gear selectors,

3.remove bolts that hold the starter motor and push starter motor back

4. Remove remaining bolts around the bell housing

5. Place jack on wheels under the gearbox pan and jack up (At this point you may want to drain the gearbox oil prior to using the jack to make the gearbox lighter)

6 remove gearbox rear mount bolt and nut

7.Gently pull the jack backwards and remove the gearbox and bell housing

8. Remove clutch assembly from flywheel by unbolting the securing screws.

9.remove flywheel and get it machined. Replace the spigot bearing.(6002V bearing).

10. refit flywheel with a bit of loctite 243 on the nuts and tighten to approx 65ft/lb.

11. Fit new clutch plate and flywheel and use a clutch aligning tool while doing this. It is so the shaft lines up with the cluth plate.

12. Remove old clutch thrust bearing and clips from bell housing and clean up the shaft and bell housing. Fit new thrust bearing with a light smear of grease on the shaft where the bearing slides and grease the shaft spline lightly. Carefully put the clips in either side of the thrust bearing and attach to the pivot. Check the bearing pivots smoothly by moving the clutch lever back and forth.

13. Align gearbox on the jack and insert into the clutch assy.

14. if gearbox is not going in far enough for bolting up, have someone put a wrench on the engine bottom pulley(harmonic balancer) and gently rock back and forth while you manouver the gearbox shaft in.

15. When shaft and gearbox has gone in as far as possible start bolting up and this will pull the gearbox in the remaining 5-10mm. Bolt up slowly and sequentially so the gearbox is being pulled in evenly.

16. Refit starter motor and tailshaft. Check everything is reconnected and bolted up. Gearbox oil top up.

17 adjust clutch cable if needed.

As far as clutches go this is a straightforward job that needs approx 4hrs to reassemble once you have all the parts and flywheel machined. You only need basic tools 13mm ,14mm, 17mm, 12mm sockets and socket extensions , 15/16" socket for gearbox pan. Ring spanners for tailshaft, Pliers.