Anyone changed a Peugeot Expert clutch?

[kev b]

My best mate has asked if I can "give him a hand" to change the clutch and DMF on his 2010 Peugeot E7 Eurocab (same as Fiat Scudo/ Citroen Relay), i.e. he watches whilst I fit it.
Is this a job that can be done without a lift or is it going to be a nightmare?
I can't find any info on the 'net apart from the official repair time of 5 or 8 hours depending on who you believe.
It looks as though you might be able to pull the box sideways and do the job without removing the box completely but on the other hand I might need to drop the subframe/remove exhaust suspension & brakes etc.

[Fish981]

Never done one but Autodata and AutoVista both say 8.5 hrs and both headlights, inner wings and subframe have to come off. I suspect he wont get much change out of £1000 if he's having the DMF done as well. How good a mate is he?

[robminiman]

do them all the time at work, there not to bad really. if you loosen the bolts in the gearbox side of the subframe and lever the frame down 2 inch and chock it then once the box is unbolted it can just be pushed to the side and tied into the gap whilst the clutch/dmf is changed.

[kev b]

Thanks Robminiman, would you care to explain further and earn a virtual drink?
How long is the job doing it that way?

Edited by kev b on Saturday 15th December 17:19

[robminiman]

if the engine is a 1600 and your doing it ont floor with a jack expect to take a fully day, if its a 2liter then id say 5ish hours.

heres a nice little cheat on the 1.6, instead of removing the heat shields and cat etc ( about 1 hourish work) there is a bolt about half way up the bell housing on the engine side 13mm head, crack it loose with a spanner and then cut the head of the bolt off with a air hacksaw or hacksaw blade. other than that theres nothing to drastic just the usual stuff. any questions just ask

[kev b]

Thanks, it's a 2 litre hdi. So it's just disconnecting the neccessary, then moving the box out of the way by lowering the subframe 2 inches and pulling it into the wheelarch then?
Thanks again - Kev B

[robminiman]

yes fairly much what, id get a crankshaft oil seal just incase its leaking once your in there, the last 1 i did was a crank oil seal leaking making the clutch slip on a 2.0 police dog van. was a very very interesting road test wearing my high viz jacket

[kev b]

Thanks Robminiman, I'll have ago at this tomorrow, the clutch isn't slipping but the flywheel sounds like a cement mixer with a kerb stone in it.
Confidentially though, the answer I was looking for was "no way - take it to the dealer" never mind, I'll let you know how I got on when it is finished - look out for a post on Friday!

[kev b]

Finished this yesterday, as people have said, it is basically a straightforward but very time consuming job. However in common with most Peugeots I have encountered over the past 35 years this vehicle seems to have been designed by someone with the purpose of making simple tasks difficult. My bucket of swearwords (well stocked) was empty after the first hour. Firstly, every type and size of fastener seems to have been employed at random then arranged so that three or four items must be removed to access them. The lower wishbone for example is secured with six bolts and requires six diferent size spanners to remove it, the anti-roll bar needs the whole subframe dropping to renew the bushes (not available from Peugeot, you must buy the whole bar!) and the gearbox has no level plug. The whole job took way longer than it should because of the malevolent arrangement of components. On the bright side though we changed the anti-roll bar bushes and a lower arm whilst we were about it, so that has saved another day off the road.
Would I do it again? Well if it was summertime and I didn't have severe man-flu, armed with the knowledge I have gained then maybe.
Incidentally the DMF went from perfect to totally knackered in an afternoon, the clutch at 80K miles was about half worn. The flywheel was so badly damaged that the access holes for the securing bolts were way out of line and we had to cut it off with a grinder.