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240 Clutch:~

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Old Aug 23rd, 2018, 18:06   #1
Bob Meadows
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Last Online: Yesterday 20:26
Join Date: Sep 2017
Location: STANDISH LANCASHIRE
Default 240 Clutch:~

How to change a 240 clutch
Mike_Brace :~ Original Post.

Just to add to this advice: ~ I have only recently done the same exercise on my F reg. 240.
The clutch has been changed without the advantage of a lift or a pit, it has been completed on the garage floor by supporting the front on wheel ramps and the rear on axle stands- when finished you will feel as though someone has beaten you up but it can be done! I had to do this alone so that made it even harder.
I found that the top bellhousing bolts couldn’t be reached from the engine bay but by using the flexible socket fittings & extensions they are better removed from the exhaust downpipe side under the car- in fact quite easily once the engine is at the lowest point.
A trolley jack is a must to take the weight in lowering the box and for installation once the new clutch is in.
I made up some locating pins from old bolts but found that in this situation under the car they had to initially be removed whist the box is being maneuvererd but once lined up correctly you can use them to support the box.
The box had a rope support at the rear through the gear lever hole and this took some adjustment to get the angle right. I did struggle initially to line everything up but once you twist the box so the starter motor housing point is at the low point and the use of a torch and mirror through the small gap between the engine & box making sure that the shaft is entering through the clutch centrally life becomes easier! The trolley jack makes for fine adjustment here and aids the final push - the box went home quite quickly from that point.
The clutch socket head bolts came away quite easily (but I did initially apply some heat to each just in case Loctite had been used- these have been replaced with hex head bolts and a little Loctite (low torque) as no spring washers are used.
The reverse light cable needs to be watched in terms of dislodging itself from the switch (top of the box) and difficult to get at if this happens- I had to retrace my steps here as the reverse lights failed- make sure the connections are tight and that the original cable tie is replaced stopping any cable movement when the gear lever is replaced.
Fortunately all the bolts on this project came away without problems and only required a light clean but no rust.
Technically straight forward and no real problems- garage floor procedure is achievable if you take your time and have the paracetamol handy!! The wife just pretended to be interested!
Regards Bob

Last edited by Bob Meadows; Aug 23rd, 2018 at 19:38.
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