Clutch failure- help please

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fastjet
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Clutch failure- help please

Post by fastjet »

Firstly, hope you all had a good xmas.
Sadly the clutch has started slipping on my 2004 2.0 HDi (110 bhp), so I am seeking advice from the kind folk on the forum before jumping in.
I was contemplating doing the change myself, but wondered how difficult that would be to on a drive way. Any idea how long it might take and are there any special tools required?
Thanks.
Last edited by fastjet on 30 Dec 2018, 12:31, edited 1 time in total.
Nemo26
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Re: Clutch failure- help please

Post by Nemo26 »

Have changed clutch twice on a drive way, not too dificult, but you neeed all standard tools, wrench sockets, radial seal sleeve, and if you have self adjusting clutch you need toll to press the clutch against flywhel. How long it depends on skills, screws condition etc, i have managed from my c5 x7 remove gearbox in 2,5 hours. One day is usualy duration
fastjet
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Re: Clutch failure- help please

Post by fastjet »

Hi, thank you for your reply. I thought that all C5's had self adjusting clutches? Which part is the radial seal sleeve?
Nemo26
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Re: Clutch failure- help please

Post by Nemo26 »

Thats not a part that is tool that you have to make yourself. You have to change radial seal in gearbox drive shaft cover. It must be installed in oposite direction. Local citroen shop sells only covers with already installed seal for about 55 euros. Seal alone is about 6 euros. You can install new seal with help of self made tool (sleeve) and press. Remember seals with rubber around should always be installed lubed on outer side.
411514
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Re: Clutch failure- help please

Post by 411514 »

It’s a relatively easy job as clutches go, perfectly do’able on a driveway with a good tool collection. No special tools, it’s not a self-adjusting clutch, or at least not in the sense that the pressure plate springs compensate for wear, so you don’t need a SAC tool. I don’t know what the radial seal sleeve tool the previous poster refers to is, perhaps it is required for the posters x7 but not for your mk1. You might wish to change the gearbox input shaft seal and/or the engine crankshaft seal at the same time, but it’s not necessary to do so, both seals seem to last in excess of 200k miles. If you are changing the dual mass flywheel as well you would ideally use the Citroen DMF centering tool, let me know if you will be and I can find a part number. Some sources reckon that you need a special tool for releasing and engaging the release bearing with the clutch fork, but you don’t, you can manage with a long screwdriver or thin pry bar. As a first time changing the clutch on the driveway give yourself two days and you should have plenty of spare time to find dropped bolts and drink tea.
411514
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Re: Clutch failure- help please

Post by 411514 »

N.b. You need to remove the gearbox from the engine bay (from below) to get at the clutch - unfortunately you can’t just move it aside like on some cars, and you need to remove both driveshafts and so split both hub-lower arm ball joints.
Nemo26
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Re: Clutch failure- help please

Post by Nemo26 »

If it's not SAC, you are fine to go.
fastjet
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Re: Clutch failure- help please

Post by fastjet »

Thank you to everyone for the helping.

I thought that C5 clutches automatically adjusted to compensate for wear.
Is it possible to manually adjust a C5 clutch?
Thanks
411514
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Re: Clutch failure- help please

Post by 411514 »

No manual adjustment, or at least nothing I know of, presumably the hydraulic circuit compensates for wear to the extent that the bite point remains at the same point of the pedal travel, but SAC typically refers to the pressure plate springs having some adjustment relative to pressure plate face to keep spring angle and so pedal feel constant despite wear to friction disc.
fastjet
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Re: Clutch failure- help please

Post by fastjet »

Thanks for the help.
citroenxm
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Re: Clutch failure- help please

Post by citroenxm »

You can do it with the box in the car. If you are going to remove the box from the car and you have the lift up collar for reverse remember to disconnect the reverse gate cable from the box. If you do the clutch with the box in the car by moving it over it is possible but its a very very tight squeeze and when I did it I broke the flywheel sensor on top of the bell house so remember to remove that too.
I did a 2.0 8v hdi all in situ. But I did need a hand to get the box back on.
fastjet
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Re: Clutch failure- help please

Post by fastjet »

Thanks for the advice.
If I do the change with the box in, do you slide the box straight back from the engine or to the side to make enough room?
citroenxm
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Re: Clutch failure- help please

Post by citroenxm »

You move it sort of under the passenger cross beam.. Ie straight off the engine towards the passenger wheel.. Assuming your in the UK with a rhd car
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Pug_XUD_KeenAmateur
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Re: Clutch failure- help please

Post by Pug_XUD_KeenAmateur »

I did a clutch for the first time back in Winter 2014 on my 405 na D.

Sticking points I noted on that were....
having a socket and bar big enough to undo the Hub Nuts (35mm in my case). Undo these before you jack it up

...and having the centre-ing thingy to ensure the clutch plate is central*

It was also damn awkward to get back the 'box back in, only about 25Kg or so, but the limited access made it feel double that weight.

It took me 3 days, which sounds a lot I guess, but that was my experience; I was working kerb-side and I do tend to be a bit slow, especially first time round. Good luck !

*I never did get my hands on one, which is perhaps why I've got issues with it just 50k (ish) miles later; so anyone who's got one they're willing to part with, do let me know.

NB: also satisfy yourself that its worth spending the money on it if you're gonna pay a Garage to do the job, eg that its not got rust issues that could force it off the road in the next year or two.
fastjet
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Re: Clutch failure- help please

Post by fastjet »

Many many thanks, the advice is so helpful.