busy couple of days coming up

[del97td]

on the way to work this morning the clutch pooped it self so inbetween working all weekend the wifes birthday and getting hold of the parts including orings and rear main seal and burning the midnight oil pulling it apart o joy.

[arotovegan]

Had to do mine a year or two back. Can be difficult to find a clutch for the diesel at a reasonable price. I got an LUK kit off micksgarage in the UK. I just had a look and they only have a Japanparts kit now:

https://www.micksgarage.com/d/clutch...rts-clutch-kit

Not sure of the quality of Japanparts but it's relatively inexpensive.

If you don't already know the OEM part numbers:
Clutch kit: 5874175
Rear main seal: 5010817AA although you should be able to find a generic RMS and o rings.

Also, just a thought, is your rear main seal leaking badly? If not, I personally wouldn't bother taking of the flywheel and replacing seals. Maybe it's just me but I've had a bit of trouble getting it all sealed up properly and the leak probably wasn't really bad enough to justify the effort I put in. If you do decide to do it, I have the torque specs for doing up the flywheel somewhere.

Good luck!

[layback40]

Many XJ diesel owners have tried the quick clutch replace without doing the seals. If you do that chances are you will be back again doing the seals.
The RMS needs to be replaced with a viton seal.
The Oring at the end of the cam is often the cause of oil leaks. Make sure you back it up with a ring of silicone around it. Some times the adapter housing between the engine & gearbox is slightly deformed around the bolt holes near the cam. If it is, best you flatten the surface with wet & dry & diesel. This will improve your chances of not having an oil leak.
The alan key type bolts that hold the rear main housing need new lock washers as well as new alan bolts. They can come loose & cause bad oil leaks.
Use plenty of good quality high temp silicone & it will seal ok.
When I did my clutch I got an EU made one off the shelf.
Its worth replacing the clutch fluid while you are at it. Often clutch issues are the hydraulics & not the actual clutch.

[del97td]

thanks guys, got all the bits through work,except the flywheel bolts. bit of a bitch those two torx head bolts at the top

[arotovegan]

yea those are a pain. I'm assuming you have got them already but I was able to get them by going in from the top at the back of the engine.

[layback40]

Originally Posted by arotovegan

yea those are a pain. I'm assuming you have got them already but I was able to get them by going in from the top at the back of the engine.

I use 1/2" drive ratchet socket with about 2' of extensions. Drop the back of the gearbox down a bit to help. You can replace them with bolt heads if you dont have a good torx set. They dont need to be done up that tight.

[del97td]

got it all apart had to use a die grinder down the back of the engine to get
one bolt out (took forever) rear main has left a bit of a mess
hard part now is trying to get the flywheel bolts theyre a discontinued part
nothing available