Posted by Keith in Washington [24.41.55.51] on Thursday, June 11, 2015 at 11:15:53 :
In Reply to: Re: clutch removal posted by pw58 [204.112.126.40] on Thursday, June 11, 2015 at 09:02:26 :
You do not need to tip motor. Remove floor boards, center hump, drive line, and brake and 4x4 shift levers. Remove lower and front covers of bell housing. Use an extension and remove top transmission bolts. Replace top bolts that are longer and have heads cut off. This allows you to slide and align the input shaft better. Remove lower transmission bolts. Place transmission jack under transmission and wiggle the transmission to the rest off the longer upper bolts then lower to ground when input shaft clears.
Now go after the clutch. Loosen 2 bolts about 1 turn then rotate flywheel and loosen the next bolts. Keep going until all bolts are removed. Always loosen bolts just a little as you go around the pressure plate as the will prevent you from warping the pressure plate. With the last bolt removed the clutch disk and pressure plate will come out.
Check the flywheel for any significant scoring. If it needs resurfacing then the bell housing needs to come out which is not really easy. If the flywheel is not scored I clean it really well with brake cleaner and denatured alcohol. I will often take 400 or 600 wet dry sand paper on a small sanding block and clean the flywheel. The reclean with brake cleaner. Clean the pressure plat surface really well also before installing. I also clean the inside of the bell housing if it has been hit by oil. Check the bushing in the center of the fly wheel and replace if necessary.
Install is the reverse of taking it apart. Use a good clutch alignment tool. Use a new throw out bearing. Slide the clutch disk and pressure plate in and install bolts as you rotate the flywheel. Again tighten tighten each bolt just a little as you go around the flywheel. Slide the trans onto the headless top bolts making sure the throw out bearing is correctly positioned. If you can't get the tran all the way against the bell housing. Rotate its output shaft to align the splines as you slide the trans forward. If it still won't go in the last little bit push the clutch in a little which will allow the clutch disk to move a little as you slide the trans forward. Do not use the trans bolts to force it in the last little bit. Once it is against the bell housing install lower bolts then remove head less upper bolts and put the upper bolts back in. Put the rest back together.
It is not too tough of a job. Just a little time consuming. If you have to take the bell housing off to get the fly wheel resurfaced, then as PW58 said the upper bolts on the bell housing are difficult to get at. It can be done with the engine in place, but I say the heck with it and pull the engine which I can do in about 2 hours if I have help lifting the front clip off. I rarely have to pull the fly wheel, usually the clutch is slipping due to being oil sparked.
Don't get a rebuilt clutch disk. Get a new one from DC on this forum.
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