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advice please connect clutch fitting

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advice please connect clutch fitting

Postby johnxr318 » Sat Nov 11, 2017 10:04 pm

hi am after a bit of advice on fitting a clutch kit to my transit connect van lwb 2006 i fitted clutch before to escort xr3i and fiesta before so am going to try to fit one advice please
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Re: advice please connect clutch fitting

Postby g-man » Sat Nov 11, 2017 10:05 pm

a lot easier using ramps :wink:
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Re: advice please connect clutch fitting

Postby flyingclutchman » Mon Nov 13, 2017 12:20 pm

The layout is similar to the escort you've done, but the gearbox is a lot heavier and it obviously is fitted with a concentric slave cylinder and cable gearchange. There's two things to consider. Once the gearchange cables are disconnected remove the gearchange turret as a unit. You can't really do this until the mounting bracket is removed so leave it till the end of the dismantling. The gearbox is a very tight fit in the subframe. Undo the exhaust joint and wedge a piece of wood behind the engine to keep it pushed forward. Oh and don't forget to put a plastic bag or similar in the hole where the gearchange turret goes in case anything drops in.Good luck
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Re: advice please connect clutch fitting

Postby Piglet » Mon Nov 13, 2017 4:37 pm

I'm glad someone brought this up, I've got to do mine.
Is this vid any good?
https://www.youtube.com/watch?v=1eoUL347ce0

There are 4 parts, so it's either thorough, or full of shite.
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Re: advice please connect clutch fitting

Postby flyingclutchman » Mon Nov 13, 2017 6:06 pm

Well it's a video about doing a 2002 focus so lots of it won't be any use. I'm not sure what they are doing but it's a hell of a long video. The connect isn't the easiest clutch to do but it isn't particularly technical. It's mainly just heavy and awkward. I can't really do you a blow by blow account but I can help if you get stuck. Most importantly you need decent tools which would include: 2x axle stands. Comprehensive set of metric sockets. 10,13.15,17,19,21mm will all be needed. Set of torx sockets, 8mm allen key or socket. 32mm socket pref. in 3/4 drive with appropriate bar. Spanners to complement the sockets and 2 trolley jacks or one if you are under 50 and have strong biceps. If you don't have at least this equipment pay someone else to do it!
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Re: advice please connect clutch fitting

Postby Boghopper » Mon Nov 13, 2017 10:51 pm

This is comes in three parts and is pretty informative: https://www.youtube.com/watch?v=2CUeiCEheaM
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Re: advice please connect clutch fitting

Postby Piglet » Tue Nov 14, 2017 3:36 pm

Nice find, The Focus one was out the archives from this forum, from a long while back mind.
In vid 3 it takes him a couple of goes to get the box back in & lined up, and that's with a hydraulic stand.
I noticed also that he splits the N/S inner CV rather than removing the complete shaft. Why?

There was also another vid on Connect gearbox removal, photography looked a bit amateur.
https://www.youtube.com/watch?v=AoiVkeEFvnU
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Re: advice please connect clutch fitting

Postby Piglet » Tue Nov 14, 2017 11:56 pm

Had a better watch of it which answered D/S question.
Good video.
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Re: advice please connect clutch fitting

Postby flyingclutchman » Wed Nov 15, 2017 12:51 pm

I watched a few minutes of the video to see what the driveshaft issue was. I'm not surprised he couldn't get the shaft out, they don't usually just come out by levering, they need a sharp impact. It is quite tight to get in, but you can get a slim cold chisel in behind the cup then hit hard with a club hammer (levering against the bottom of the box) and it will release. It's also much easier to move the starter out of the way. As the battery is out this is easy enough
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Re: advice please connect clutch fitting

Postby Piglet » Mon Apr 16, 2018 10:42 pm

Digging this old thread up again.
I've made a healthy start but the N/S drive shaft is stubborn.
Why does the O/S slide straight out but not the N/S?

I'll clear some stuff away and try the cold chisel thing tomorrow.
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Re: advice please connect clutch fitting

Postby Boghopper » Tue Apr 17, 2018 8:55 am

I had to replace my N/S driveshaft a few months ago and the only way I could release it was to remove the O/S one and drift it out with a 1/4" diameter bar, going straight through the gearbox. After fighting with it for a whole day, it came out within five minutes by coming through from the other side.
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Re: advice please connect clutch fitting

Postby Piglet » Tue Apr 17, 2018 4:08 pm

Does that work?
Why 1/4", does it have to pass through something?
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Re: advice please connect clutch fitting

Postby Boghopper » Tue Apr 17, 2018 4:53 pm

Yes, it does work. The O/S driveshaft comes out easy just loosen the intermediate bearing housing and the wishbone ball-joint end and it will just pull out. I didn't even undo the outer driveshaft/wheel bearing nut. Anyway, once the O/S driveshaft is out the way you can peer into the gearbox and see the end of the driveshaft. You can only hit it at about the '11 o'clock' position, if I remember correctly as there is a metal pin obscuring the rest of the driveshaft end. You need a strauight piece of bar (mild steel) as you don't want a brittle steel as the ends can chip and drop into the gearbox. Mild steel is soft and will just bruise, rather than chip. Just make sure it is straight/true and around 3/4"/ 6mm diameter and about 14" long. Make sure you seat it nicely on the exposed part of the driveshaft you can see through the hole and give it a smart blow. Mine didn't just pop out, I had to keep on tapping it out bit by bit, whilst turning it through a quarter a turn a few times. Anyway, it was out after five minutes, after I had spent hours and hours using bars/ levers etc from the N/S. Do you have a pit or anything? Because you will need to look through the gearbox with a torch to see the end of the shaft and place the drift correctly. I don't think this would be possible lying on your back, or on car ramps.

If I was having to do another N/S driveshaft again. I would try to do it by pulling/levers for a few minutes only, I wouldn't bother wasting hours and hours on it. I would drift it through from the other side again and not mess about.
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Re: advice please connect clutch fitting

Postby Piglet » Wed Apr 18, 2018 7:24 am

That must be top tip of the week, award yourself a gold star and a light ale!
My bit of 1/4" rod got wedged between the splines and the diff axle, I had to wiggle it out.
I would suggest 6mm.

I'm guessing the N/S is a pain because it has a clip which the O/S doesn't have because its held in by the intermediary bearing.

Clutch is out.
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Re: advice please connect clutch fitting

Postby Boghopper » Wed Apr 18, 2018 9:33 am

Well, It was something I read on the internet a while back after I had spent hours trying to remove my N/S shaft. I have written 3/4", I meant 1/4" but, maybe 6mm is better, I cannot quite remember. I just remember it had to be the exact right size and I was hunting around looking for a piece in my garage. Yes, it is the circlip. Some seem to lock in the box, you simply cannot move them unless you drift them out from the other side.
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