Day 2.............
RAIN WINDOW
CLAYT SHOT
Tried to cheer Asylum up a bit, not sure if i would of backed this Jockey.........
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
Stripped down Clutch fork mechanism. The Mechanism slides off the main shaft sleeve, once you have released the spring.
SPRING
Give the fork etc a good clean
BEFORE CLEAN
Coated with some waterproof grease and re-assembled.
AFTER CLEAN
New bearing..........Loverleeee!
NEW BEARING
Removed clutch housing from flywheel and old clutch plate emery clothed flywheel and degreased.
EMERY FLYWHEEL
DEGREASE FLYWHEEL
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
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
TOOL AND PLATE ALLIGNED
CLUTCH HOUSING INLINE
LOCTITE
HOUSING BOLTED UP
REMOVE TOOL
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
SPRING
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
TRANNY ANGLE2
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
TIME FOR A TEST DRIVE
THE HONOUR WAS ALL MINE.......
THEN IT SNOWED.....LARDIE OWNER DRIVING A JEEP :-x
