I think it's clutch replacement time... - Page 2

DMGRS · 13th March 2024, 14:56

Smashing work (especially labelling all of the bolts - takes time, but very much worth it) and thank you for your order!
Hopefully the re-assembly goes nice and smoothly.

These aren't a fun job at all, and to be honest are the reason I picked an automatic 75 - with my back being the way it is (at the tender old age of 34...) I couldn't do a clutch change myself these days.

Give us a shout if you need a hand with anything else,
Mat

gnu · 13th March 2024, 16:48

Interesting post, keep the pics a reports coming. 🍿

Tourist · 14th March 2024, 17:35

Thanks for the replies chaps - and for the parts, Mat.

I never want to do this job again! It's been pretty hardcore - even things that should have been simple have been a right pain in the neck. Getting the new master cylinder in is a job that seemed like it should take about 20 minutes, but actually took over 2 hours by the time we'd routed the copper pipe and re-seated the outer grommet.

Today's job was getting the gearbox back on and it took most of the day - not an easy job lying on your back, working on the car while it's on axle stands. In the end, we attached a chain to to the top of the box using the bolt holes for the top mount, then slung a rope through the chain and used a block of wood across from the slam panel to the suspension turret to brace it on.

My dad held that in place while I got under the car, gently rested the gearbox on my arm (it's actually not that heavy) and then I was able to lift it up and get it seated correctly on the end of the engine. It was a bit of a lump to bench-press, but not actually that bad.

I feel like we're on the winning end of things now - I've got to torque the engine to gearbox bolts up first thing tomorrow, then it's time to get the subframe back in place.

I'm hoping to have it all back together tomorrow so I can get the wheels aligned at the weekend. Apart from the subframe, it's all stuff that I've had apart before so I know how it goes back together.

One other thing I have to do is fill the master cylinder with brake fluid and then bleed the clutch hydraulics. I'm wondering if I can squirt it back up the pipe into the master cylinder and then quickly screw the quick-release union on, prior to bleeding. I guess it's not *that* bad a job to fill the master cylinder inside the car and just operate the pedal a few times.

Wish me luck!

Tourist · 14th March 2024, 21:58

The video I made this morning, prior to wrestling the gearbox:

https://youtu.be/R_WrUzUnMU4

Tourist · 15th March 2024, 19:31

Not sure if anyone is still reading, however, the good news is that today I got most of the parts back on the car - it was fun getting the subframe back on single-handed while my dad was busy at the dentist!

Tomorrow I'll be putting the starter motor back on and bleeding the clutch hydraulics, followed by checking the torques on all the bolts and fitting the rest of the miscellaneous parts such as the battery box, engine cover, undertray etc. then it's off to the tyre place for a wheel alignment.

I'll report back when I'm victorious, hopefully some time early tomorrow afternoon.

JAYWHY 75 · 15th March 2024, 19:57

Quote:

Originally Posted by Tourist

The video I made this morning, prior to wrestling the gearbox:

https://youtu.be/R_WrUzUnMU4

A good video and some very good pictures previously- once you get the car back together any chance of pictures of the old parts - it will be interesting from my point of view to get an idea of the general wear and tear of the used parts.

YHT · 16th March 2024, 13:03

I squirted from the blled valve back to the master cylinder; seems OK for several months. A rag under the master cylinder and the cap a bit loose to allow the air out.

Tourist · 16th March 2024, 14:54

Cheers for that info!

I was going to give it a try, but have fallen at the first hurdle! I left the pipe disconnected in the engine bay, without the non-return valve fitted and then filled the reservoir of the master cylinder, but try as I might, I couldn't get it to pump fluid.

I've taken it off the car and compared old with new, and my old master cylinder pumps a good squirt of fluid, but try as I might, the new one refuses to.

My thinking is that I may have a defective part, but not being an expert in such matters (this is the first one I've changed) I am not sure...

Rather frustrating as the rest of the car is more or less back together.

YHT · 16th March 2024, 17:26

Oh Dear is the comment that should get through the editors but read stronger feelings.At least the master cylinder is a bit easier than the slave. Good luck.

Tourist · 16th March 2024, 18:15

Thanks for the commiserations - oh dear is more or less what I said, haha.

Here's the video I made this evening, showing the master cylinder problem, and the condition of the old clutch components:

https://youtu.be/KrSqTF0ZcFU

13th March 2024, 14:56	#11
DMGRS Discount MG Rover Spares Rover 75 CDTi, 2x MG ZS180 Join Date: Jun 2011 Location: Hythe, Southampton Posts: 11,320 Thanks: 456 Thanked 3,377 Times in 2,027 Posts	Smashing work (especially labelling all of the bolts - takes time, but very much worth it) and thank you for your order! Hopefully the re-assembly goes nice and smoothly. These aren't a fun job at all, and to be honest are the reason I picked an automatic 75 - with my back being the way it is (at the tender old age of 34...) I couldn't do a clutch change myself these days. Give us a shout if you need a hand with anything else, Mat __________________ Your trusted MG Rover specialist! Tel: 02380 001133 / Email: [email protected] We now have a 'chat' function on our site for even quicker replies. Give it a try! Remember - discount code FORUM5 for 5% off

13th March 2024, 16:48	#12
gnu Gets stuck in MG ZT Join Date: Apr 2018 Location: Bristol Posts: 696 Thanks: 332 Thanked 164 Times in 133 Posts	Interesting post, keep the pics a reports coming. 🍿 __________________ gnu

14th March 2024, 17:35	#13
Tourist Loves to post 2004 Rover 75 Tourer CDTi Join Date: Apr 2016 Location: Fulbourn, Cambridge Posts: 455 Thanks: 105 Thanked 123 Times in 101 Posts	Thanks for the replies chaps - and for the parts, Mat. I never want to do this job again! It's been pretty hardcore - even things that should have been simple have been a right pain in the neck. Getting the new master cylinder in is a job that seemed like it should take about 20 minutes, but actually took over 2 hours by the time we'd routed the copper pipe and re-seated the outer grommet. Today's job was getting the gearbox back on and it took most of the day - not an easy job lying on your back, working on the car while it's on axle stands. In the end, we attached a chain to to the top of the box using the bolt holes for the top mount, then slung a rope through the chain and used a block of wood across from the slam panel to the suspension turret to brace it on. My dad held that in place while I got under the car, gently rested the gearbox on my arm (it's actually not that heavy) and then I was able to lift it up and get it seated correctly on the end of the engine. It was a bit of a lump to bench-press, but not actually that bad. I feel like we're on the winning end of things now - I've got to torque the engine to gearbox bolts up first thing tomorrow, then it's time to get the subframe back in place. I'm hoping to have it all back together tomorrow so I can get the wheels aligned at the weekend. Apart from the subframe, it's all stuff that I've had apart before so I know how it goes back together. One other thing I have to do is fill the master cylinder with brake fluid and then bleed the clutch hydraulics. I'm wondering if I can squirt it back up the pipe into the master cylinder and then quickly screw the quick-release union on, prior to bleeding. I guess it's not that bad a job to fill the master cylinder inside the car and just operate the pedal a few times. Wish me luck!

14th March 2024, 21:58	#14
Tourist Loves to post 2004 Rover 75 Tourer CDTi Join Date: Apr 2016 Location: Fulbourn, Cambridge Posts: 455 Thanks: 105 Thanked 123 Times in 101 Posts	The video I made this morning, prior to wrestling the gearbox: https://youtu.be/R_WrUzUnMU4

15th March 2024, 19:31	#15
Tourist Loves to post 2004 Rover 75 Tourer CDTi Join Date: Apr 2016 Location: Fulbourn, Cambridge Posts: 455 Thanks: 105 Thanked 123 Times in 101 Posts	Not sure if anyone is still reading, however, the good news is that today I got most of the parts back on the car - it was fun getting the subframe back on single-handed while my dad was busy at the dentist! Tomorrow I'll be putting the starter motor back on and bleeding the clutch hydraulics, followed by checking the torques on all the bolts and fitting the rest of the miscellaneous parts such as the battery box, engine cover, undertray etc. then it's off to the tyre place for a wheel alignment. I'll report back when I'm victorious, hopefully some time early tomorrow afternoon.

16th March 2024, 13:03	#17
YHT Loves to post Rover 75 Saloon Join Date: Jun 2017 Location: suffolk Posts: 264 Thanks: 46 Thanked 25 Times in 23 Posts	I squirted from the blled valve back to the master cylinder; seems OK for several months. A rag under the master cylinder and the cap a bit loose to allow the air out.

16th March 2024, 14:54	#18
Tourist Loves to post 2004 Rover 75 Tourer CDTi Join Date: Apr 2016 Location: Fulbourn, Cambridge Posts: 455 Thanks: 105 Thanked 123 Times in 101 Posts	Cheers for that info! I was going to give it a try, but have fallen at the first hurdle! I left the pipe disconnected in the engine bay, without the non-return valve fitted and then filled the reservoir of the master cylinder, but try as I might, I couldn't get it to pump fluid. I've taken it off the car and compared old with new, and my old master cylinder pumps a good squirt of fluid, but try as I might, the new one refuses to. My thinking is that I may have a defective part, but not being an expert in such matters (this is the first one I've changed) I am not sure... Rather frustrating as the rest of the car is more or less back together.

16th March 2024, 17:26	#19
YHT Loves to post Rover 75 Saloon Join Date: Jun 2017 Location: suffolk Posts: 264 Thanks: 46 Thanked 25 Times in 23 Posts	Oh Dear is the comment that should get through the editors but read stronger feelings.At least the master cylinder is a bit easier than the slave. Good luck.

16th March 2024, 18:15	#20
Tourist Loves to post 2004 Rover 75 Tourer CDTi Join Date: Apr 2016 Location: Fulbourn, Cambridge Posts: 455 Thanks: 105 Thanked 123 Times in 101 Posts	Thanks for the commiserations - oh dear is more or less what I said, haha. Here's the video I made this evening, showing the master cylinder problem, and the condition of the old clutch components: https://youtu.be/KrSqTF0ZcFU