Outer Limits 4x4 Board

Have had a search and looked in bible.

Has anyone got any hints or tips regarding replacement procedures for the clutch in a 4.2 Diesel Clutch. Other then pay someone to do it.

Planning on using an engine crane through the window and sling through the shifter hole.

Thanx
Dazza

yep ive just removed my box this way, except i used 2 lengths of chain, one at the front and the other at the rear of the box.

i also removed the transfer case beforehand to stop it twisting due tothe weight on one side.

a tip is you will need around 500mm in 1/2 inch socket extensions to get to the 2 upper bellhousing - engine bolts, this is done through the shifter hole in the floor.

i should be installing a new clutch this weekend if it arrives in time, hopefuly i can get the flywheel machined tomorrow.

read most threads on it... most people say they wouldnt do it again.. they are fawkin heavy, and even with a crane, they are a real bitch of a thing.
Helped a mate do 2 now, and told him to fawk himself doing another.

I would rather pull the motor out, do clutch, crank seal, fit turbo ect in one hit.

Pulling the motor is easier than the transmission. I've done it both ways and will always pull the motor in future. The flywheel will probably have some heat cracks - machining should sort these out. Shop around for clutch kits - they are expensive for the 4.2D and prices vary a lot. Best I found was $400 for a PBR kit from repco after some haggling.

could also get a big trolley jack and lift out the cup on the end (the part that contacts the car when jacking) and make a cradle to fit in it that sits neatly under the gearbox/transfer - no need to remove the transfer that way, have done plenty of mq boxes that way on my own, nice and easy to get it to the right height and roll the jack forward lining up the spline.

Just use a bottle jack and a peice of wood to support the back of the motor, which can also be handy for re aligning as you can raise or lower the motor a couple of cms each way.
Probably just me but never seemed like to good an idea putting an engine crane through the window just seems too awkward having a strap through the floor manouverability wise?!

i didnt do it through the window i did it with my door open.

yeah i did the jack under the sump trick on mine.

i made a cradle for my trolly jack which is only a small one, but i didnt trust it for the gearbox.

Well Ive got all of mine out and so far its all been pretty easy, prob only taken 2-3 hrs. Gotta get my flywheel machined, so will sort that out this week and hopefully will be back together next Saturday

Dazza

i did it through door with engine crane u need at least two ppl to get it back in and a shitload of pushing i have to twist it to get the lug for the startermotor to clear the firewall and i held on to the rear of the car and pushed it with my legs makes it a bit easier good luck getting it in was harder than getting it out

I spent a couple more hours on it last night, got box bolted back onto motor and will hopefully finish it of today.

Didnt take the transfer case off and did it on my own. Bit of messing around with one person but definately doable.

Dazza

mines also back in, all the hard stuffs done now its just the intirior.

i found it alot easier to get in then out., the sealant on my bell housing - engine was damn strong.

my clutch is a clutch industries 4 terrain, cost $400

http://clutchindustries.com.au/range/4t ... lutch.html

it helps when your brother works at a nissan dealership

checkout the box it came in, will make a great recovery gear box

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Cool box, but is urs a pretty colour?



Mines all done, interior and everything now, ot a bad job wouldnt want to do it every day, that sealant is a bit of a pain got it all over the place when putting it back in.

Clutch is no heavier than before and no slippage as before.

Dazza