"Terrance" - 04' Terrano II SE Commercial 2.7TDi Project Thread

[Bigbunny2007]

The tools look upto the job in my opinion and you are tackling the job in the correct way :thumb2
Working on your back changing a terrano clutch is a big job and one many people would not tackle so take great credit from it mate.
Your sharing your personal experience too and it will help others in the future which other forum users will appreciate. Every day is a school day and nobody knows it all

 

[Banshee]

For those of us not so learned as others with all things clutch related, I grabbed a few books off the bookshelf and did a bit of swatting on the way to the cinema :thumbs

I hope this diagram helps from a fantastic book I have called "The reluctant motor mechanic"

 

[jims-terrano]

Well done so far Banshee and as for anything else that has been posted I can't imagine for one minute any offence was meant. Sometimes things don't read the way they were meant to do.

Keep up the good work:thumbs

 

[emjaybee]

For those of us not so learned as others with all things clutch related, I grabbed a few books off the bookshelf and did a bit of swatting on the way to the cinema :thumbs

I hope this diagram helps from a fantastic book I have called "The reluctant motor mechanic"

That's what I wanted to know! I never imagined the mechanism worked that way around, my logical brain had the internal parts operating the other way (I know what I mean!).

Top job.

:thumbs

 

[solarman216]

I'm not shy of learning Rick,

I need positivity and pointers, not riddicule as to how crap my tools are :doh

I apologise unreservedly Zac, I had a very bad day yesterday and did not word my reply properly, I did not mean to critisise in any way, also excuse spelling i never could spell and my spell checker on this site is not working, Rick

 

[Banshee]

I apologise unreservedly Zac, I had a very bad day yesterday and did not word my reply properly, I did not mean to critisise in any way, also excuse spelling i never could spell and my spell checker on this site is not working, Rick

No problems Rick, no offence taken really. I find my spell checker in Chome doesn't work on the forum either

 

[makeitfit]

Love this site.
I learned pretty much all I know about Terrano mechanics from this here site. Love it , and the confidence it's given me to keep making things fit (eventually) :lol
As said, every day's a school day :thumbs
Years ago there were some on here that were very up themselves if I tried something different and it didn't work etc lol
I'm sure Rick was just being a little matter of fact while typing at the same time as spinning the lid off a malt :beer
Go Banshee

 

[Banshee]

Had a few hours spare this evening so had another crack at the car

I've managed to remove the centre exhaust section now, thought I would get away with not doing it at first.

Removed the Gearbox breather and also removed the wiring from the twisty metal clips and tucked it away for safe keeping.

Removed the gear stick, that was a tricky one removing the circlip without having 3 hands :lol

I have struggled to see how I remove the transfer lever though :nenau It looks like I have to remove it by taking the whole thing intact with the mechanism from the side of the gearbox?

Apart from the transfer lever, I've got a few more tricky bolts to remove from the bellhousing and disconnect the Crankshaft Position Sensor and the gearbox should be ready to come away from the car :thumb2

The workbench just keeps growing

Looks like best access to the other bell housing bolts and CPS are from the top with the intercooler remove in the engine bay :doh

 

[emjaybee]

FM bloke!



Is there anything left ON your motor?

:lol

 

[Banshee]

FM bloke!



Is there anything left ON your motor?

:lol

It's a big bloody job :lol

I feel like I'm close now though just hope I don't have to maul with this gearbox for too long

 

[makeitfit]

All those parts off the truck can be lovingly checked over , serviced and painted up before refittng
Check your front prop for wear.
Also did you take a pic of how the gearbox loom was plugged ? I didn't and although they're all p,lugged in again, I'm not convinced they're right ??
When you get to the gearbox removal on your dolley thing, make sure you use a strap or similar to stabalise the transfer box as it's so far offset it's the twisting you need to be careful of.
Good luck :thumbs

 

[Banshee]

All those parts off the truck can be lovingly checked over , serviced and painted up before refittng
Check your front prop for wear.
Also did you take a pic of how the gearbox loom was plugged ? I didn't and although they're all p,lugged in again, I'm not convinced they're right ??
When you get to the gearbox removal on your dolley thing, make sure you use a strap or similar to stabalise the transfer box as it's so far offset it's the twisting you need to be careful of.
Good luck :thumbs

Cheers Pete :naughty

Can't really get the order of the plugs wrong but I did take pictures beforehand in case :lol

Yeah Rear prop needs a new UJ one end, should have done them both really when I had it off a few months ago but I was being a cheapskate.

Front prop UJ's seem OK

Yeah the removal and re-fitting of the box is the only thing that has me worried

 

[elty001]

Getting it off is the easier part.
Lining it up and re fitting requires a bit more precision but slowly and carefully wins every time :thumb2
Also I got hold of a big sheet of plywood and lay that on the floor under the jack so the floor is nice and level and makes manoeuvring the box on the jack easier :thumb2

 

[solarman216]

I go with the plywood on the floor, and as Pete says make sure it is strapped to your cradle real tight with good packing where needed, also I would fit out riggers to the jack as the width is not enough for stability with this heavily ofset box, take care getting it out, I would just slide it back so you have just enough room to change the clutch that way it cannot drift too far sideways, as you pull it off of the engine take particular note of any front/back tilt movement, if there is any adjust it now and push the box back in, if you have not got it aligned now you will never get it back in once the new clutch is in, tip put the box in 4th gear, then you can insert the rear prop and so turn the spigot shaft to align the splines, but most important of all is once the shaft is in the centre plate, any more than an inch or so of up/down.sideways movement at the rear of the box and your new clutch will be ruined, it is a big job, so as others have said slow and easy, think you may now see why I prefer to remove the engine it is simply hanging there and any angle adjusting is easy, with no danger of damaging the clutch due for instance to the box slipping on the cradle, Rick

 

[Banshee]

Getting it off is the easier part.
Lining it up and re fitting requires a bit more precision but slowly and carefully wins every time :thumb2
Also I got hold of a big sheet of plywood and lay that on the floor under the jack so the floor is nice and level and makes manoeuvring the box on the jack easier :thumb2

I go with the plywood on the floor, and as Pete says make sure it is strapped to your cradle real tight with good packing where needed, also I would fit out riggers to the jack as the width is not enough for stability with this heavily ofset box, take care getting it out, I would just slide it back so you have just enough room to change the clutch that way it cannot drift too far sideways, as you pull it off of the engine take particular note of any front/back tilt movement, if there is any adjust it now and push the box back in, if you have not got it aligned now you will never get it back in once the new clutch is in, tip put the box in 4th gear, then you can insert the rear prop and so turn the spigot shaft to align the splines, but most important of all is once the shaft is in the centre plate, any more than an inch or so of up/down.sideways movement at the rear of the box and your new clutch will be ruined, it is a big job, so as others have said slow and easy, think you may now see why I prefer to remove the engine it is simply hanging there and any angle adjusting is easy, with no danger of damaging the clutch due for instance to the box slipping on the cradle, Rick

Thanks for the hints there guys :naughty

4th gear and Plywood!!!!! Check they are both great shouts

 

[Banshee]

So close I can taste it!!!!

I'm almost ready to pull the box away from the truck now.

Got under tonight and removed the x2 12mm nuts and x1 15mm nut that hold the transfer box lever to the side of the box, easy when you know how :doh I thought it would come away in the same manner as the gear stick.

Next was onto the last 2 bell housing bolts, right in the middle was the CPS, I decided initiallty that best access to them was from behind the engine and the bulkhead again from the top, so off came the intercooler but the gap was just rubbish and its painful on your knees balancing on structural bits

I decided that maybe Alan had it sussed and continued to try and get at them from in the car with a load of extenision bars but I didn't have enough and had to play clever, I used x2 1/2" Extension Bars, a 1/2" knuckle joint and a long reach 14mm socket and went in for some funky angles and got the result :naughty

I've now modded the garbox cradle to my trolley jack and started to play with position tonight, not still quite sure yet where everythings going to go but I have a few ideas and I'm going to play see what feels best and works best for re-alignment, certainly going to employ a few straps, a lot of wood and another jack into the equation

Being so close has me wondering what my clutch internals will look like as unlike Alan I still had drive (of sorts), should I be expecting an intact friction plate just very worn :nenau

 

[solarman216]

Just been reading back and note you say your jack "sinks" after a while, this you cannot afford, once you have it at the correct height, cut a wedge from wood or steel that you can jam in there to stop it sinking, Rick

 

[Banshee]

Just been reading back and note you say your jack "sinks" after a while, this you cannot afford, once you have it at the correct height, cut a wedge from wood or steel that you can jam in there to stop it sinking, Rick

I've sorted ut out now, it was low on oil, I've topped it up and bled it :thumb2

 

[makeitfit]

Don't forget to put some stabalisers on your trolley jack. You're about to create a very unstable situation :thumb2

 

[solarman216]

Don't forget to put some stabalisers on your trolley jack. You're about to create a very unstable situation :thumb2

You are behind, said that in post 616, Rick