Clutch

[Janie]

Do any of you know anything about fitting a new clutch that isn't in the haynes manual!
They make it sound a bit too easy, but I don't want to start taking Daisy apart only to find I can't do it after all!

[newagetraveller]

Changing the clutch is relatively easy. The important part is that you need either a first motion shaft from an old gearbox or the correct tool (which almost nobody has) in order to make sure that the driven plate is centralised within the clutch cover. Otherwise the gearbox will not fit onto it.

The hard part is removing either the gearbox or the engine.
The gearbox is easiest to remove if you have a pit in your garage, otherwise it can be quite difficult. This has been discussed in the old website under:
technical>mechanical>gearbox removal
Otherwise, to take the engine out, you need some sort of hoist capable of supporting the engine.

PS How did you get on with the door handle?

[Chris Morley]

I too wish car repair procedures were as simple and straightforward as the Haynes Manuals make out. Basically, they were based on the Haynes engineers dismantling a brand new car, with all the necessary tools and a nice dry, well lit garage. Even so, their 'simple' procedures are usually far more involved.

The harsh reality is that doing this with old & worn tools on a cold winter's day is hard work and unpleasant due to the oil, dirt and rust you're going to get covered in. It depends on whether you enjoy this kind of activity and if you can't spare the £200 or so labour charges a specialist will charge.

[Willie]

agreed, the worst part is separating the
engine and gearbox. If you do do it then
beware......the clutch plate must go on the
right way round, it is marked "Flywheel"
if you get it wrong you cannot operate the clutch.Many people have got it wrong Willie

[Janie]

After much deliberation and soul searching, I decided to put my feminine wiles to work and stood by Daisy, peering around her engine and looking a bit lost. Lo and behold I now have lots of helpful men all booked in to help me on saturday! It appears that chivalry is not dead after all........(now I just need to see if this ruse also works with the washing up!)

[newagetraveller]

More things not in the Haynes manual

Gearbox removal

The gearbox is supported under the car by a crossmember. This is held in place by four bolts screwed into captive nuts inside the chassis legs. If these nuts are rusty they may turn when you try to unscrew the bolts. You then have to remove the gearbox cover (which takes ages)and use a mole wrench to hold the nuts inside the chassis legs while you undo the bolts.

Engine removal

a. It is only necessary to remove one engine support bracket (I go for the offside one) but the four bolts holding it to the chassis can be very awkward to undo.
b. The job is easier if you have some of the engine lifting hooks which fit under the rocker cover securing nuts.
c. When lifting the engine it must be supported so that it doesn't tend to tilt either forwards or backwards but stays level.
d. You will need a jack that is short enough to go underneath the gearbox to lift and support it.
e. If you get c and d right the engine will come away from the gearbox easily. If you get them wrong it will all be a big struggle.

Good luck!