Post by: Warthog on March 26, 2008, 12:39:59 AM
RAIN WINDOW
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000584.jpg)
CLAYT SHOT
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000599.jpg)
Tried to cheer Asylum up a bit, not sure if i would of backed this Jockey.........
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000589-1.jpg)
Jet washed Gearbox and Tranny assembly, ready for new parts! Block up all electric connectors and Gearstick tunnel.
Found the offending part for the noise!
OLD BEARING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000615.jpg)
Stripped down Clutch fork mechanism. The Mechanism slides off the main shaft sleeve, once you have released the spring.
SPRING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000620.jpg)
Give the fork etc a good clean
BEFORE CLEAN
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000579.jpg)
Coated with some waterproof grease and re-assembled.
AFTER CLEAN
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000622.jpg)
New bearing..........Loverleeee!
NEW BEARING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000613.jpg)
Removed clutch housing from flywheel and old clutch plate emery clothed flywheel and degreased.
EMERY FLYWHEEL
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000630.jpg)
DEGREASE FLYWHEEL
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000632.jpg)
Checked main shaft needle bearings. It was O.k this time. No signs of contamination/damgage, so we left it alone. You will need an internal bearing puller to get the little bugger out.
FLYWHEEL NEEDLE BEARING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000641.jpg)
Installed new clutch plate and housing, Need to align the clutch plate up with the bearing in the fly wheel centre. I made up an allignment tool. Most kits are supplied with an alignment tool in the US.
With alignment tool inplace the housing can be bolted up. Used loctite threadlocker on the bolts. Remove alignment tool once bolted up. torque values are in the manual.
ALIGNMENT TOOL LOCATES IN BEARING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000649.jpg)
TOOL AND PLATE ALLIGNED
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000652.jpg)
CLUTCH HOUSING INLINE
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000653.jpg)
LOCTITE
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000656.jpg)
HOUSING BOLTED UP
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000653.jpg)
REMOVE TOOL
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000659.jpg)
Assemble Clutch fork, with new bearing in Bellhousing. The Spring can be a little bugger to get right. Once assembled check that all slides O.K
ASSEMBLY
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000662.jpg)
SPRING
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000663.jpg)
Clutch housing bolted up to flywheel with Clutch plate aligned and the clutch fork assembly complete. You are ready for the fun and games of re-assembly of the hole lot. Get GB/Tranny underneath and prepare to line it all up. The 2 dowels to which the main 2 bolts go through are your main guides.
Due to the engine sitting at an angle, the GB/Tranny unit is best set at a slight downward angle. We temporarily located the gearshifter back in the box to put the box in gear. This locked up the main shaft to aid realignment to clutch plate splines.
TRANNY ANGLE1
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000665.jpg)
TRANNY ANGLE2
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000668.jpg)
At this point you will either be lucky and it will all slide nicely together or you will be fettling the lump around till you get it right. Dont go at it to Bullish as once you have the alignment right it will locate easily. Once located get the main bolts in and tight. We rotated the flywheel a little while using forward pressure to aide the locating of the main shaft in the Clutch plate.
Thats it!
Bolt it all up, re-assemble the trans linkage, Gear shift and connect wiring, dont forget your crank sensor! Install Slave cylinder then Props. Then assemble the skid plate mount, to the Gearbox, slide exhaust mount from cat into location. Raise and position skid plate to the Rubber mounts and chassis, and tighten
SKID PLATE
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000694.jpg)
TIME FOR A TEST DRIVE
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000706.jpg)
THE HONOUR WAS ALL MINE.......
(http://http://img.photobucket.com/albums/v11/Tenbulls/P1000709.jpg)
THEN IT SNOWED.....LARDIE OWNER DRIVING A JEEP :-x
Post by: Bubba on March 26, 2008, 04:55:17 AM
Post by: Bioman on March 26, 2008, 09:50:34 AM
Post by: MK1 on March 26, 2008, 10:08:37 AM
Now, was that shirt entirely necessary?
Post by: daggie on March 26, 2008, 10:36:00 AM
Post by: Asylum on March 26, 2008, 11:29:45 AM
Quote from: "daggie"
eggselent write up :lol:
So do I. a torx socket but there's no room to swing a little pinky!! 8-)
Post by: daggie on March 26, 2008, 01:51:41 PM
Post by: Tragic on March 26, 2008, 02:39:19 PM
Even with a fookin great extension and the correct socket (E11 I think....) I've found that on a YJ if you lower the back of the engine enough to get to the bolts, 9 times out of 10 you will snap off the temp guage sensor as it fouls the bulkhead....... :shock:. I now have gearbox replacement down to a fine art, can do it on my own from start to finish in about 1 1/5 hours :weep:
Post by: daggie on March 26, 2008, 02:43:10 PM
Post by: Dave69 on March 26, 2008, 10:49:34 PM
Post by: Tragic on March 28, 2008, 12:58:07 PM
Quote from: "daggie"
that thing needs putting down, Tragic :lol: :lol:
I think you're right :twisted: