Jeep Wrangler Forum banner

first time clutch instalation ?s

3K views 46 replies 13 participants last post by  c5wagner 
#1 ·
well after searching my fingers off thought i would ask for some helpful hints on replaceing my clutch,,,i have all the bolts out except the top one behind my valve cover,,..can anyone lead me to a helpful pic by pic step for replacing my clutch...my yj is a 94 with 5 speed tranny,,

my flywheel was making some wracket then bam went the clutch , i plan on replacing with a clutch kit,,,what else should i do while im in there ?

any and all help will be greatfull...thanks
 
#2 ·
autozone has a duralast clutch set,,,,is there anything i should be aware of
 
#4 ·
Go with a LUK clutch from pep boys. Find out the part number and search eBay as well;,I found a good deal for mine.
 
#5 ·
Get a luk clutch kit, also, if you dont have a slide hammer to remove the pilot bearing, use wet toilet paper packed in instead of grease or bread. Makes cleanup easier and it works better than either
 
#6 ·
The Haynes repair manual is sum what informative on replacing clutch. A transmission jack is a must for this job. I made a 2*2 wood platform and bolted it to my spare hydraulic jack along with cargo straps to hold it down. Take your time and work smart; its really not that hard to do.
 
#7 ·
Try a YouTube video there is a ton of them

Trans jack at Harbor Freight $75 and you will use it for 100 other things once you have it

It can take some time and don't be in a hurry
 
#10 ·
thanks a ton guys for the link to the info,,great to know which kit to buy also
the only thing i am missing is an xtra set of hands..lol
 
#11 ·
Lower the transmission a bit and the bolts are pretty easy to access. I couldn't get my pilot out using the grease method so i rented a slide hammer from autozone. I also ordered my luk from amazon for 85 bucks.
 
#12 ·
thanks mikey,,

and as of now i have no idea about wet toilet paper or bread...lol
 
#13 ·
My grandpa showed me the toilet paper trick when I was younger. Grease makes a huge mess and makes everything harder to grip, and bread works but is usually too thick to get packed in right. I use a slide hammer now since I bought one, but if it's a trail fix, I'd use wet toilet paper before anything.
 
#14 ·
im still wondering,,where and how u use the toilet paper....or bread,,,
i know alot of things to do with both but...not anything on what im doing..lol

thanks again guy,s....im getting ready to go out and start taking more bolts out..
im just one guy and have hardly any tools or what im doing,,except for the link to the video..,,,,thanks again for that...

should i take the transcase off the transmission ? i have read not to and also heard you should....

learning as i go with the help from you guy,s----===thanks again to all of you..

i was going to sell this yj but its got way to much good about it to sell..i plan on really fixing this one up and the clutch is not gonna stop me....lol
 
#15 ·
You would pack the wet toilet paper into the pilot bearing hole and use a metal rod, bolt or dowel that fits tightly into the pilot bearing hole and hit it with a hammer until the pilot bearing comes out, you might have to pack it, hit it, pack some more and hit again until it comes out.

Heres a video, just use use toilet paper instead of grease How to remove a clutch pilot bearing without a pu…: http://youtu.be/28bSl4r1kwQ

As for the transfer case removal. I'd remove it if you didn't have a transmission jack or keep it attached if you have a transmission jack.
 
#16 ·
X2 on having a trans jack. I didnt have one but i had help lifting everything. It was hard getting the trans back in even with help. Had to wiggle the hell out of it while turning the output shaft to line up the splines. That was with two large guys, trans dry and x fer case removed. Jeep was on jack stands high enough that I could sit in there. Make sure to support your engine from the oil pan. I had my engine/trans leaning pretty far back so the bolts were quite visible and I could get a torque wrench in there.
 
#17 ·
Lol, I've lifted the transmission in and out without a jack on the trail by myself. The internal slave decided to blow right on the trail. Getting it back in is the most difficult part of the job. Line up the splines before lifting it, and make sure you're putting it in as straight as possible.
 
#19 ·
Bench pressed it from the ground into place and got the dowels set then bolted it. It took me about 3 trys to get it set though. Still not my most difficult trail fix I've done. That would be the on trail gear setup for a friend haha. Using a bottle jack and the vehicle frame as a press was hard
 
#22 ·
Lots of good advice, so far.

I'd replace the front transmission seal at the same time.

Since yours is a 94, you already have external slave - otherwise, I would have recommended the internal to external slave swap.

I used this transmission jack from HF:
Transmission Jack - 450 Lb. Capacity


As noted above, you'll find many more uses for it. I originally bought one of their larger jacks, but found it to be too large and annoyingly sloppy. I returned it and got the smaller one.
 
#23 ·
a big thanks to everyone,,as of today i took my exhaust off and through all the other junk i had to do besides working on the jeep i was able to take the t/case out..
just the 2 bolts holding the tranny in with a jack under it aswell..
maybe tomarrow i will get the tranny out..im really in no hurry just learning as i go
thanks again everyone...

i actually had this jeep listed on cl for sale but when i started hearing the throw out bearing i never renewed it.....now i have decided to keep this one and give it a full make over...the dooms day machine...lol i just named her...
 
#25 ·
well after about a week of not working on the clutch its still sitting in the driveway with only 2 bolts holding the bellhousing on..from under neath the reversed torx bolt rounded smooth at the 11oclock position..i bought a set of easy outs but there not grabbing good enough to loosen it up,,,,i have soaked it with pb blaster and waited still stuck..anyone have any other tricks up there sleeve on how i can get this last bolt out...i have tried and tried..
i got the new LUK just waiting to go in,,,but this bolt is the only thing keeping me from dropping it out....
i have taken a week off of working on it ...spending some good QT with the grandsons hanging out at carter cave state park..,,having a blast in the 50deg. caves while its in the upper 90s ...lol
 
#26 ·
well after about a week of not working on the clutch its still sitting in the driveway with only 2 bolts holding the bellhousing on..from under neath the reversed torx bolt rounded smooth at the 11oclock position..i bought a set of easy outs but there not grabbing good enough to loosen it up,,,,i have soaked it with pb blaster and waited still stuck..anyone have any other tricks up there sleeve on how i can get this last bolt out...i have tried and tried..
i got the new LUK just waiting to go in,,,but this bolt is the only thing keeping me from dropping it out....
i have taken a week off of working on it ...spending some good QT with the grandsons hanging out at carter cave state park..,,having a blast in the 50deg. caves while its in the upper 90s ...lol
only thing left really (if you cant get the easy out to grab)

what i did with my jeep, one of the driveline bolts(which are way smaller) snapped off inside the yoke, so i had to find a drill bit a little smaller than the Outside Diameter of the bolt and had to do the best i can to drill straight eventually the drill got stuck inside the bolt because of metal shavings getting clogged in the driil.

i then put the drill in reverse and it broke it loose( con is that i couldnt get the bolt off the drillbit, but whatever)

be verry verry careful with this approach not to drill sideways in any direction otherwise you might be re tapping a hole.

if you dont feel comfortable with this approach id have a shop pull it out. at least then if they mess up its their fault
 
#28 ·
thats been my last resort thought,,,but there is just bearly enough room to get a socket on it using every exctension i and my family owns just to reach it..lol..
thanks again guys...
 
#31 ·
I would suggest buying a second socket to fit the bolt, lowering the tranny enough to access the stuck bolt, then tack welding the socket onto the rounded off bolt. If you can not get to that bolt to tack weld the socket to it with the tranny lowered, you can try raising the tranny as far as you can and tack welding it from above.
 
#32 ·
i will try that,,,i have several sockets so no real loss..
i have time to start working on it again monday,,,---that thing is coming out no matter what it takes,,,,,im missing the yj now..lol
but i have had 9 days of Q.T. with the grandsons...from fishing,hicking, and spelunking adventures..there first real cave spelunking....great time,s..

thanks again to all,,,,im sure i will need more advise putting it back tgogether..lol
then im starting the rebuild on the body and some other mods. i love wheeling it and i never really needed a pretty one because of where i take it daily.and a farming tool ..but now i want to really fix her up down to shooting it a different color ....since i have decided to keep to keep it..i might aswell make a killer looking yj---aka dooms day machine...lol
 
#33 ·
well after fighting with this frigging rounded off bolt i think im going to have to pull the engine out just to get it out....uuuggg..
but since i have decided to keep this one and have plans on painting her up might aswell pull the engine and clean up the 4.0 and paint it aswell,,that way i will have a nice clean and fully repainted yj.,,,,for a few days anyway untill the next mudhole gets in my way...lol
this will also be my first time doing this...at 53yrs old im wanting to work on this stuff
be like teaching an old dog new tricks...lol
 
#34 ·
Im currently stuck on the E12's at 11 oclock and 1 oclock. I have everything else out except these and they're really pissing me off. Ive lost enough knuckle skin to give MIchael Jackson a new face (if he was still around). I only have enough extension to go approx. 12" which may be my problem per the other posts so it looks like another trip to Autozone. And the trans jack is costing me $35 damn dollars a day. Any other suggestions?
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top