1987 escort 1.6 d clutch

[squazy84]

Has anyone on here replaced the clutch on one of the old 1.6 diesel escort mk3? I was looking for a few tips before I jump head first into it?

 

[johnik]

not too difficult really BUT....when you pull the driveshafts,poke a rolled up piece of strong cardboard rolled in through where you have pulled the first shaft from and into the pinion gears on the diff or it will fall to bits and leave tears all over the floor.
rear "french horn" style gearbox mount can be a pain and is best removed completly.
when you re-attach the gear sellector rod,do it in reverse or you will spend to much tea drinking time trying to get it adjusted right.

 

[pedrobedro]

Car up on axle stands as high as you can, engine hoist or make something to hang the engine on failing that prop it but hanging is better. Drop the bottom ball joint out and pull the strut and driveshaft out of gearbox and put a dummy plug (piece of brush handle) in the hole or the diff bearing can drop. Take the gearbox mount out and then undo the bolts round the bellhousing and lower the engine to an angle where the box will pull off. All the other bits like disconnect battery and remove starter and other stuff in your way obviously applies but it's not too bad a job if you have the tools and patience. It's years since I did one.
As John says the box is easiest to set back up in reverse.

 

[squazy84]

Cheers lads I have her over the pit with it on a sliding Jack and overhead gantry supporting the engine,there's very little gap between box and chassis leg so it looks like I'll have to drop engine and box a bit first

 

[squazy84]

not too difficult really BUT....when you pull the driveshafts,poke a rolled up piece of strong cardboard rolled in through where you have pulled the first shaft from and into the pinion gears on the diff or it will fall to bits and leave tears all over the floor.
rear "french horn" style gearbox mount can be a pain and is best removed completly.
when you re-attach the gear sellector rod,do it in reverse or you will spend to much tea drinking time trying to get it adjusted right.

How does that happen? This is a 1987 1.6 not 1.8?

 

[johnik]

How does what happen ?
you dont need to drop the engine,keep it high as poss,there is no spigot bearing therefor a very short input shaft on the box,only needs to come out about 2 inches then drop.

 

[colnerov]

Hi, I have seen it done without taking the driveshafts out. Disconnect the N/S suspension leg from the TCA at the balljoint, Undo the O/S driveshaft nut, then leaving the shafts in move the box over away as far as necessary to clear the input shaft from the clutch. Then change the clutch, it is a bit like being a Gynaecologist so if you want a bit more room undo the N/S hub nut and swing the leg off the driveshaft before moving the box over.

Colin

 

[johnik]

I have done the 4 speeds like that,best time 20 mins and that included drinking a cup of tea ,with the 5 speed there aint enough room.

 

[squazy84]

Well this certainly wasn't 20 mins,took me about 6 hours and that's the truth,the diesel gearbox is a tight fit and the car has had chassis repairs that reduced the gap even more between the gearbox and chassis, I didn't remove the gearbox just hungry it from another chain dropped engine down and slide the gearbox under chassis leg and rotated it, drishafts undone but not removed,they aren't bad by modern standards but compared to Toyota of the same era they are like a horse and cart.