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Old 12-27-2018, 08:58 PM
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Clutch replacement (pics)

Just finished replacing the clutch in my TJ. My throwout bearing was making an awful noise so it had to be done. Clutch noise (video)

I did the job myself with basic hand tools, a floor jack, jack stands, and a harbor freight transmission jack. It was a PITA but I'm glad I did it. I saved a ton of money (Luk clutch kit was $84) and now the Jeep drives and sounds great.

Here are the guides I followed during the job that helped a lot:
https://4x4xplor.com/clutch.html

Here are some pics:

Old clutch assembly


Bell housing


Removing pilot bearing


AX5 Transmission and transfer case




Worn out throwout bearing



Bell housing cleaned up and new throwout bearing installed


New Luk clutch assembly


Transmission ready to be bolted back up


The jeep itself


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Old 12-27-2018, 09:12 PM   #2
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Looks great. What was your total time?

Thanks.

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Old 12-27-2018, 11:23 PM   #3
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I estimate about 4 hours in mine. I also rebuild the trans so I had everything apart for about 3 weeks. I would say 10 hours in total for everything. The battery powered impact guns are amazing and have really helped me for bellhousing bolts.
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Old 12-28-2018, 12:50 AM   #4
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Nice job.
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Old 12-28-2018, 08:34 AM   #5
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Your undercarriage looks so clean. Definitely save a ton of $$$ doing it yourself. Well done.
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Old 12-28-2018, 09:37 AM   #6
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Nice work. It’s not a horrible job. Just a pain getting to some of those bolts on the tranny.
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Old 12-28-2018, 09:43 AM   #7
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Nice work!
I am building up the courage to tackle this myself in the late spring, when warm weather returns. Clutch is OK, but throw-out bearing makes noise until everything warms up.

Will time it so I can do transmission mount, clutch kit, u-joints replacements and clean-up my skid plate and frame where it is covered by the skid.

Is this do-able with one person in the driveway, rather than two-people in an ideal garage set-up?
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Old 12-28-2018, 11:08 AM   #8
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did you have the flywheel resurfaced?
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Old 12-28-2018, 01:33 PM
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Quote:
Originally Posted by dbbd1 View Post
Looks great. What was your total time?

Thanks.
Two full days and that was taking my time (watching tutorial videos, running to the store to get certain tools, cleaning the bell housing, etc.). Now that I’ve done it once I could probably do it again in under a day.

Quote:
Originally Posted by SurfKaster View Post
Your undercarriage looks so clean. Definitely save a ton of $$$ doing it yourself. Well done.
Appreciate it!! Yea a pressure washer and fluid film works wonders, although I’ll probably do something about the rust where the t-case skid plate mounts to the frame.

Quote:
Originally Posted by hpclayto View Post
Nice work. It’s not a horrible job. Just a pain getting to some of those bolts on the tranny.
Yea, the passenger side bell housing bolts were a pain to get to because the exhaust is right there in the way.

Quote:
Originally Posted by tzukows View Post
Nice work!
I am building up the courage to tackle this myself in the late spring, when warm weather returns. Clutch is OK, but throw-out bearing makes noise until everything warms up.

Will time it so I can do transmission mount, clutch kit, u-joints replacements and clean-up my skid plate and frame where it is covered by the skid.

Is this do-able with one person in the driveway, rather than two-people in an ideal garage set-up?
I did it myself in the garage with only a floor jack, 4 jack stands, and a cheap transmission jack. It’s a pain but definitely doable I’d say

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Originally Posted by newheep View Post
did you have the flywheel resurfaced?
No, these flywheels aren’t supposed to ever be resurfaced because they have a convex shape which would be taken away if resurfaced. And either way, it was in perfect condition so I didn’t touch it.
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