quadeyquade Posted November 6, 2008 Report Posted November 6, 2008 Does someone one want to list a step by step how-to? I have to put my new one in in the next week or so, would love some guidance so i don't forget something. btw its for a 4age Quote
damo101 Posted November 7, 2008 Report Posted November 7, 2008 you need to get something to hold the engine up while your taking the g/box out..jack the car up and put it on stands (just the front will do) undo bottom ball joints, take drive shafts off, undo all the wiring and thermostat housing on top of the gearbox, remove speedo drive, undo selector cables, remove starter motor, undo clutch slave cylinder and tie it off out of the road, undo the back gearbox mount, place jack under gearbox, undo front g/box mount, undo side g/box mount (near the battery which should be disconnected before you start anything) jack the gearbox up so it has tension on it and is at the same level as the motor, undo the bell housing bolts, gently remove the g/box from the engine (it may get stuck on the dowels in the engine where the bell housing bolts up so get a screwdriver and gently lever it out, MAKE SURE IT DOESN'T SLIP OR ROLL OFF THE JACK, lower jack to ground height and remove from the engine bay. undo clutch from the flywheel.undo the pressure plate bolts evenly, if you have access to a rattle gun bonus, if not you will have to find a way to take the flywheel off (i use a bent valve (90 degrees) and put the collet end into a bell housing bolt hole on the motor and the other end onto the starter ring to stop it from turning and use breaker ar to undo the bolts. get the flywheel machined as always when replacing a clutch. bolt the flywheel up to the correct torque settings (same as ae82 4age) clean the flywheel bolt thread and apply a tiny bit of loctite to the threads. with your new clutch you should get an alignment tool to align the clutch plate up on the flywheel, if not you can use your fingers and check how much more you need to move the clutch plate by feeling the clutch plate and then move it so its even on the pressure plate at all sides.. put the gearbox into gear (any) and it will go in heaps in easy..put some grease onto the input shaft in the gearbox, replace the throw out bearing (should come with clutch kit) put some grease on the "fingers" of the clutch fork. install gearbox the same way as removing but make the dowels line up before you tighten the bell housing bolts.you can get one bolt in tight and it will stay in place..always make sure the flywheel surface is clean from grease and shit..it can take a while to do but you save alot in dough DIY'ing it. Quote
quadeyquade Posted November 7, 2008 Author Report Posted November 7, 2008 Thanks damo101, hopefully i don't darn it up too much :) Quote
damo101 Posted November 8, 2008 Report Posted November 8, 2008 (edited) you should be alright..just ask any questions if your unsure though. Edited November 8, 2008 by damo101 Quote
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