Clutch
Well, due to the dreadfull noise (sounds like someone using a pepper mill rather quickly) coming from Asylums TJ. The luverly task of replacing the thrust bearing and clutch were inevitable.
Jacked up the Truck and made sure we had some good room to work in. Safety first though! On blocks, with wheels chocked and Axle stands just incase.......
SHOT OF TRUCK
Asylum, said that with some 44's and Portals this type of ground clearance would make him happy!
SHOT OF CLAYTON
First to be removed was the Battery then Starter Motor:
STARTER
Then onto the rear prop
REAR PROP
Once removed, could then Support transfer case ready to remove skid plate. If you remove the skid plate without supporting the driveline. You will end up in trouble, as the plate is the main support....
PLATE OFF, REAR SUPPORTED
FRONT SUPPORT
Remove Front prop, taking the plate off makes getting to the tranny end sooo much easier!
FRONT PROP REMOVE
Disconnected all electrical plugs from Transfer and Gear box. The gearbox bellhousing has the Crank sensor to remove. Transfer case has, Speedo, 4wd light, oil pressure, Lambada sensor on cat. Plus transfer breathe pipe.
TRANSFER CASE WIRING
Remove Clutch Slave Cylinder, zip tie to chassis. Remember not to depress the Clutch peddle, or the plunger will pop out from the slave cylinder!
SLAVE CYL
Removed skid plate mount from gearbox, the rubber mount had split and needed replacing anyway. Plus the 4 main bolts were gonna be where we would support the Gearbox and Tranny, when removing. Removing the plate also helps as the rubber mount for the exhaust was seized solid, this would of caused some swearing while trying to split the bell housing from the block!
DAMAGED MOUNT
FOUR BOLTS AND GB HANGER
Removed plate from gearbox and then used an adaptor plate to bolt in its place.This would be our way of removing/splitting the Gearbox/tranny from the engine block. Simple to make, but had to sacrifice a 22mm socket to locate it in Jack.
ADAPTOR
ADAPTOR + JACK
Aligned Adaptor plate up with Garbox under truck.
ADAPTOR ON GEARBOX
JACK+MOUNT UNDER TRUCK
Now ready to start removing the neccesary bolts and final parts to get the Gearbox/Tranny split from the Engine.
Removed the Gearbox linkage and tranny selector linkage.
For the transfer selector, remove the plate as in the image. this then disengages the linkage from the transfer case. The plate is easily removed by 4 screws in the passenger footwell.
LINKAGE
PLATE REMOVED
Gearstick is pretty straight forward. From below you need to remove the dust cover and release the cap retainng the stick mechanism. Press down and twist to release. A spring is under the cap once realeased it will pop out. No drama though as it is all retained on the stick. A qiuck referal to the manual would explain this better than me!
GEARSTICK MECH
Now to the Bellhousing. 10 fasteners are needed to be removed before splitting from block. Remove all but the 2 Main bolts, the 2 either side midway up on the Bellhousing. They are the biggest bolts on the housiing, Leave them to last, once you are ready to split it.
There are 2 x Torx head screws right up at the top. These 2 "Effing" torxs will keep you busy for awhile! The way we got at them in the end was to slighty lower the Gbox to gain a little more access. If you can just crack them with a spanner, then a 1/4" Palm ratchet can get in there to remove them. We didnt have a Palm ratchet, so alot of effing and 1/4 turns with a spanner had to suffice.
TORXS
CRANK SENSOR
MAIN BOLT1
MAIN BOLT2
The lowest 2 bolts look a little over the top for holding the plate on? I would think they are for some other use too?
LOWER BOLTS
Right, with only the 2 main bolts remaining. Get ready to split the Bellhousing from the Block, this will take a bit of "Effing and Blinding" a gentle touch with a pry bar and hide mallet. I would not hit the casings though or try prying it to heavily. We found hiting the adaptor plate with a mallet gradually set it free. There are 2 locating dowels that will clear first then about another 3/4" untill the main shaft splits from the clutch plate. Then its free.........
At this point it rained and rained and rained........Sorry no piccies,
TRANNY READY TO COME OUT
RAIN
RAIN
Once the Unit is split from the Block you can now see the Clutch housing and plate on the flywheel + Clutch fork mechanism and Thrust bearing inside the Bellhousing. We dropped the GB/Tranny assembly out and rolled it into the Garage.
The Clutch could of easily been replaced with the GB/Tranny under the truck. We were cold and wet and that was enough for us for one day!
CLUTCH HOUSING
CLUTCH FORK & BEARING
IN GARAGE
