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Old November 16th, 2008, 06:38 PM   #1
Max Wedge
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Default Clutch replacement - need your tips

Okay, I haven't done a clutch (yet) on a TJ. I have an 04, with 87k on it and I'm gonna do it laying on my back in the garage.

For those of you who have done it, what would you do different? Did you pull the t/case first or leave it together? Does the bell housing stay with the trans? I looked around while I was under there tonight, and it looks as though the bellhousing to trans bolts can only be accessed when it is on the ground?? Do you leave the housing with the trans? What about the exhaust?

Anything else I should watch for, like hidden sensors, etc? Mine isn't slipping, but I think I am going to resurface the flywheel anyway, but has anyone not done it, and how did it work out?

Thanks a heap, and anyone yearning to lay on some cold concrete - let me know.
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Old November 16th, 2008, 06:42 PM   #2
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make sure you don't drop the t-case/skid and crack your exhaust header, you'll see what I mean when you get under there, the dealer did that on my 97...

seperating the t-case from the trans is "tight" ratchet wrenches are your friend (9/16"), you could skip that step and take the trans and t-case out as a unit, but it will be tougher, the t-case and trans are both pretty manageable by themselves.

If you are going to go through the work of replacing your clutch before its slipping it seems silly not to resurface the flywheel, buy new bolts for bolting it back up.
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Old November 16th, 2008, 08:35 PM   #3
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im removed my trans and transfer as a unit. not to bad but i sudjest you have a nice floack.

be sure to have your flywheel resurfaced and replace the pilot berring and throwout berring while you are at it. Clutch kits usualy come with everything but the pilot berring.

be sure to mark your trany linkage. mine had me confused by the time i got to puting it back togeather it was dark and i was hungry and tired.

you will likely need two jacks when you put it back togeather. one under the oil pan with a board in between, and the other jack for the tranny and transfer. you may have to go up and down with them to get the tranny to mate nicely

dont force the trany back on. it should just slide or pop in place once the main shaft and pilot berring line up. forcing it in can damage the pilot berring and you dont want to do it twice.

you know what they say

do it nice or do it twice!

Last edited by muddy maki; November 16th, 2008 at 08:38 PM.
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Old November 16th, 2008, 09:16 PM   #4
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Make sure you have a pilot shaft to install the clutch in line so when you do put the trans back in it slips in. Have the flywheel resurfaced, replace the pressure plate, and buy the best clutch that you can afford, or buy the best clutch, pressure plate kit that you can afford. That will get the best life from one. Rent, borrow, or steal (joking) a trans jack save allot of time and arms. While you have the trans out replace throw out bearing, pilot bearing, main input bearing, and seal on the front of the trans . Make sure you don't disconect the hydurlic hose on the clutch slave, remove it and tie it out of the way. I would disconect the exhuast pipe at the header. Follow what the other have said above.
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Old November 17th, 2008, 12:17 AM   #5
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I've done it both ways, t-case and tranny as a unit and each separately. Separately was obviously easier but it's definitely doable together. I took them out using a standard car jack with a board attached to the top, it sucked but it worked. I tried to put it back together with the jack but could get them to line up right. I ended up benchpressing it back together.

Definitely get the flywheel resurfaced. It's pretty cheap, I think I paid $35 bucks. Last time I had a shop do mine (10 years ago), they didn't resurface the flywheel and it developed a chatter immediately. Don't forget to degrease the flywheel before you put the tranny on and don't forget to locktight the flywheel bolts.
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Old November 17th, 2008, 07:10 AM   #6
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I did it on my back in the garage last spring. Kept the trans and t-case together. Wasnt that bad, that was the first clutch i had ever done. Get a trans adaptor for your jack, i should have and probably dropped the trans/t-case on me legs and body about 10 times or more.
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Old November 17th, 2008, 07:47 PM   #7
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So is the bellhousing and trans coming out in one piece?
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Old November 30th, 2008, 10:11 AM   #8
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yes^^^
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Old November 30th, 2008, 10:22 AM   #9
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be careful you don't break the short wires of your cps, when taking out the transmission. you don't want to buy one of those.
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Old November 30th, 2008, 04:24 PM   #10
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thanks! anyone else?
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Old December 5th, 2008, 05:24 PM   #11
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buy the autozone clutch. It is a lifetime warrenty. IIRC, the two bolts at the top are reverse star, so swap those out with regular hex heads. I always pull the trans and tcase apart, just less weight if you are doing it yourself.
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