Outer Limits 4x4 Board

Looks like I need a new clutch in the GQ (TD42). Was quoted about $400 labor only so I would like to do it myself but this is a VERY heavy gearbox.
Can it be done in the driveway with a trolley jack?. How many mates would I need to help? Any tips or tricks?

I did mine.

Dead easy..

use a garage trolley jack and unbolt gearbox housing off the engine block and slowly pull backwards after disconnecting the gearstick inside the car and the transfer case for ease of removal.

2 mates and a carton of beer is handy

TOM

use a good quality trolly jack.

GQ wrote:I did mine.

after disconnecting the gearstick inside the car and the transfer case for ease of removal.


TOM

Do you mean I should remove the transfer case before pulling the main gearbox, or take it out as one unit?

Mark

pull it out as one mate, its alot cleaner and easier that way. but they are bloody heavy.

Put a log through the front windows and lower the gear box down through the gear stick hole in the floor. Hope you understand that. I have done it twice with no problems to the doors.

ludacris wrote:Put a log through the front windows and lower the gear box down through the gear stick hole in the floor. Hope you understand that. I have done it twice with no problems to the doors.

with a block and tackle right?

TOM

use a crane

with a block and tackle right? Yep

I like the log idea....I wonder if those treated pine logs would be strong enough, Koppers Logs I think they are called. Could I get away without a trolley jack doing it this way and maybe even do it on my own if I have to?

Take your passenger side door off and get an engine crane and wrap a chain around it and up through the gearbox hole and lift it up clear of mounts and drop it down to the ground

Its even easier to get it back up this way too

screwy

YOU NEED SOMEONE IN THE CAR TO LOWER IT WHILE YOU SHAKE THE GEARBOX LOOSE. JUST MAKE SURE YOU SECURE IT PROPERLY AND DONT LIE DIRECTLY UNDER IT

ludacris wrote:JUST MAKE SURE YOU SECURE IT PROPERLY AND DONT LIE DIRECTLY UNDER IT

squishy....

Are there any tricks to removing the top 2 bellhousing bolts - doesnt look easy to get a spanner or socket onto them....

Are there any tricks to removing the top 2 bellhousing bolts - doesnt look easy to get a spanner or socket onto them....

yep really long extension bar and a swivel joint, most tool makers have something,

and all this talk of logs, block and takles trolly jacks makes me cringe

Don't forget the starter motor bolts.

and the wires for reverse lights/4wd light and speedo cable, i broke all these

Easiest way to get your sticks out is to remove passenger seat, console and scuff plate then lift the carpet over the sticks. Remove the surround then remove the gearstick circlip to pull it out and unbolt the transfer leaver at the pivot (Two 12mm bolts) and push it thru the floor. If you only have a trolley jack, I'd remove the transfer from the box to reduce the weight and make manouvering the box in and out easier, this can be done without draining the oil. On some models you have to undo the exhaust flange to get the engine to lean back enough. I'd also be trying to find some way of bolting or tying the box to the jack so it can't fall off.

try not to catch it on the chest, they're a bit heavy and its hard to breathe with it sitting on your chest!

Thanks for all the tips - l the box is now sitting on the ground underneath the GQ and I did it by myself and I'm not squashed! I left the x/fer and gearbox attached. I tried the universal joint/long extension on the top 2 bellhousing bolts but couldnt get it to happen for me. I ended up getting them with a spanner from the top.
I used a long piece of wood (about 4x4) through the front windows, supported outside the car with a ladder on one side and a pile of wheels on the other. I hung my block and tackle form this and wrapped a chain around the gearbox. I had to take out the steering column to get clearance for the piece of wood. I think the doors would have supported the wood but wasnt game to try it today. I had a lot of trouble getting the box to go back far enough because there is a bulge for the starter motor which kept hitting the body (floor). I also didnt have the chain around the gearbox at the center of gravity and the front of the box fell forward when I finally got it clear of the body. I will definitly have to balance it better when I put it back in. (not looking forward to this)

Just as well I took it out now as the clutch platee was worn down to the rivets.

I'm starting to think that an easier way to change a clutch in a GQ is to pull the motor, rather than the box, especially when its a one man operation. What do you guys reckon?

I've done a couple of these by myself (lots of beer and drugs), and have found that for the $400 you saved it's a cheap way of buying a trolly jack for $150 - $250 plus other tools the job can be done easily and simply.
The other trick is to pull out the foot rest, use a piece of wood under where it sits and bash out the floor pan. It can be put back into place at the end of the job and this saves the twisting of the g'box to get back in.

The other thing you can do is get the vehicle ready, tow it to the shop, have the g'box only, put in. Then tow it home and finish it off.
Sounds like a lot of dicking around but will only cost you about $60 in labour and thats the hard bit out of the road.

you are all tight arses! just pay a mechanic it saves a lot of heart ache and if they f*ck something up its their problem, where as if you f*ck it its gonna cost you, possibly injure youself! if you stuff it too much and have to tow it to a mechanic he is going to laugh at you and charge you accordingly, cos they hate finishing other peoples half finished jobs!

just my 2c haha

Sell it to a wood duck... easiest fix

the boxes are not impossibly heavy people keep saying they are. i was fitting my duels and lifted the two cases at once after i found the forklift annoying. and i'm only a weedy 5'10". i would seperate the t/case then drop it, then the box.

bru

On my soft top Landrover I just took the floor out and used an I beam & chainblock

On my Rangie, I packed cardboard boxes under it and let it crush them as it dropped, to put it back in I took the floor out & roof off