Clutch replacement - weight of gearbox

Hi all,

The clutch on my D40 will need to be changed in the short to medium term. I am considering doing the job myself. Only considering tho...

My question is this - has anyone taken the gearbox out of their D40? If so, what does it weight?

"Back in the day", it was a matter of dropping the gearbox out using a trolley jack to support it. But if the box in the D40 is too heavy, it might be too cumbersome to handle this way. Bearing in mind, I would be doing the job on the ground - the vehicle up on stands.

Anyway, looking forward to your replies.

How many k's you done doc? Much of that towing your van? I am also considering clutch upgrade but as a preventative measure, probably NPC solid. I would think the box would be a but cumbersome in a trolley jack, the workshop I work in has a dedicated truck gearbox jack which I'll be using for mine, thinking a normal trolley jacks footprint may be a bit narrow but for lack of a better option I suppose you could. I couldn't see it weighing too much, flat out 100kg tops but that's a shit load if you can't keep it on the jack.

The ute has towed pretty much on and of its entire life. And 4wding....always out bush

She's only got ~85k on the clock, but its been rough miles on the old girl. No slippage yet (fingers crossed) tho!

I'll definitely be going solid. Highest clamping pressure I can get.

If you don't mind me asking, what's your van weigh? I know it can be a sensitive topic but I get called fat all the time.....lol
Just trying to fight the paranoia of my nav being able to tow 2.5t van around Australia, hill starts suck! Can't help but feeling I'm about to get a dual mass uppercut on every launch.

Hey Flash,

She's basically 2.5T fighting weight - a little more, but let's round it to the nearest half a ton Hill starts can be interesting on really steep stuff, but I find the best way is to use some revs on the initial take-off as you slip the clutch just for that fraction, then away it goes. It's only on the very steep hills that cause any need to slip the clutch at all from what I've found. I do have a chip fitted, and have it tuned for low-rev grunt. Not sure if that makes a difference or not, as I've not towed this van without the chip installed.

Yeah I'm procrastinating chipit dominator ATM but its a big one to swallow.

If it's any help, I've had the "standard" chipit installed for over 2 years. The original harness was faulty and chipit replaced it via overnight bag. The chip itself has been faultless. I was concerned about the possibility of water damage so the chip is inside a couple of zip-loc bags with the small opening facing down (to drain any moisture which may enter). I had mine fitted by a local specialist. Not because its a difficult job, but because I got dyno work done at the same time, and they put the right "tune" in the chip to maximise the performance characteristics I was after - low down. So off-topic well and truly, but I am really pleased with the chip.

Dragging that big van up hills on the highway - I reckon the chip has helped me on more than one occasion. She just lets me hold onto a gear down to around 2 grand on even some pretty steep hills.

Cheers doc, nice to know they are capable.

Back on topic you could possibly make some sort of cradle to go on top of trolley jack to support the profile of box to help balance but the width of the base would still be a concern. I asked local brake and clutch for a quote on labour and they were very hesitant as they had just taken 2 days to do a late model hilux and done their arse on labour quote. Mate did his diesel pajero and reckons it only took a couple of hours, I'm gonna put him to the test with mine.

Good luck and thanks heaps for your guidance, might see ya on our travels.

Just had a brain fart, rent a jack!
I googled it and kennards hire have transmission jacks for hire.
Hook in buddy.

flashum1 said:

Just had a brain fart, rent a jack!
I googled it and kennards hire have transmission jacks for hire.
Hook in buddy.

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SWEET!!!! Thanks mate, you're a legend. Now it's definitely on the "do it myself" list.