ive got the "Haynes Service and Repair Manual", and the steps to change the clutch is really long. i was just wondering if there is any short cuts that i can that to make the change quicker? it just seems like not all the steps would be necessary to do. are they?
also is there anything that i should look out for e.g. other parts that might need replacing or other tips to make sure i do it right.
thanks.
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changing the clutch
Make sure you have the pressure plate,thrust bearing and clutch plate. Having a clutch alignment tool can also be handy. I have done 2 in mine, but both were done on a mates hoist.
Basically you need to do the following:
take gbox lever out from interior.
undo wires for sender from top of box in engine bay.
drop of the uni shafts from the back of the gbox + front diff.
take of the gbox brace under the box.
undo starter motor bolts / take out.
undo gbox mount (will have to support gbox after this)
pull box out (watch out for - separtate clutch/plate/bearing off and replace.
when going in:
watch out for bolt hole(they can be pain.
align clutch splines up and plate between gbox and engine.
redo list above in reverse.
cheers
Basically you need to do the following:
take gbox lever out from interior.
undo wires for sender from top of box in engine bay.
drop of the uni shafts from the back of the gbox + front diff.
take of the gbox brace under the box.
undo starter motor bolts / take out.
undo gbox mount (will have to support gbox after this)
pull box out (watch out for - separtate clutch/plate/bearing off and replace.
when going in:
watch out for bolt hole(they can be pain.
align clutch splines up and plate between gbox and engine.
redo list above in reverse.
cheers
[url=http://www.outerlimits4x4.com/viewtopic.php?p=930942#930942&highlight=]Zook[/url]
U SUK Zook Built and Sold.
New rig is 97 80 DX. 2" list 33s
U SUK Zook Built and Sold.
New rig is 97 80 DX. 2" list 33s
Best way to align the clutch is by feeling in the 3 openings where the pressure plate is away from the flywheel. You should be able to feel the clutch plate and where it is against the pressure plate (friction plate).
Ensure that it is even all the way round the plate abnd you should be able to get away without an alignment tool.
As nicbeer said - DON'T FORGET TO UNPLUG THE WIRING!!!
I seem to forget that all the time - very annoying
Ensure that it is even all the way round the plate abnd you should be able to get away without an alignment tool.
As nicbeer said - DON'T FORGET TO UNPLUG THE WIRING!!!
I seem to forget that all the time - very annoying
Also - if yoiu stick your head up in the tunnel you should be able to look straight through the splines in the clutch plate to see that it should have a spigot bearing centred in the middle - DO NOT FORGET TO CHANGE THIS BEARING INSIDE THE FLYWHEEL
If it is not changed, your car will make grinding noises when the clutch pedal is depressed.[/b]
If it is not changed, your car will make grinding noises when the clutch pedal is depressed.[/b]
I made an aligning tool from an old gearbox .. pulled the input shaft, my zuk seems to like the flavor of clutch .. it seems to eat em regular enuff ..
" If governments are involved in the covering up the knowledge of aliens, Then they are doing a much better job of it than they do of everything else "
Like said before I just stick my head up in the tranmission tunnel with a torch to align every thing. One thing to look for is the nylon washer you will see when you pull the shift lever out of the transfer. It hasnet happened to me but Ive had friends that it has perished and fallen into the case making zooky hit angel gear. All the best with it it anit a hard job.
Its a wheelbase thing
thanks for the replies guys.
i've pulled the transfer case out (had to fix a leak in it), all shafts are out and i'm having trouble with the transmission. i've got access and have loosened all other bolts on the transmission except for one on the passenger side which is behind the extractors. i'm trying to get the extractors off now but i'm having a lot of trouble. i've only gotta get out two more bolts out but they are completely rooted now. i think i've gotta grind them off, and replace them now!
i've also got a tool to help for alignment made from an old shaft, so i'm hoping that that part will go better then something as simple as removing the bolts from the extractors.
i've pulled the transfer case out (had to fix a leak in it), all shafts are out and i'm having trouble with the transmission. i've got access and have loosened all other bolts on the transmission except for one on the passenger side which is behind the extractors. i'm trying to get the extractors off now but i'm having a lot of trouble. i've only gotta get out two more bolts out but they are completely rooted now. i think i've gotta grind them off, and replace them now!
i've also got a tool to help for alignment made from an old shaft, so i'm hoping that that part will go better then something as simple as removing the bolts from the extractors.
Another quick tip is to vut a small V into the gearbox crossmemeber only needs to be about 1cm wide and 1 cm deep (and not needed on all sierras) but makes taking the gearbox out heaps easier as it clears the input shaft for the gearbox clears the pressureplate far more easily.
" If governments are involved in the covering up the knowledge of aliens, Then they are doing a much better job of it than they do of everything else "
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