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The last inch - Clutch change

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17 Mar 2026 20:59 #264023 by mlines
The last inch - Clutch change was created by mlines
So it's been 20 years since I did a clutch, I remember struggling with the lack of space to move the gearbox around. 
So I am there again with the gearbox on the SJ 

Only one inch to go. I used a clutch alignment tool but get the two to mate up again is a struggle. 

Any suggestions? 
   
Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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17 Mar 2026 22:34 #264025 by Roger Fairclough
Replied by Roger Fairclough on topic The last inch - Clutch change
I used two dowels made from cut down bolts . Screw into engine so that you can slide g/box along them into engagement. Put g/box into any gear and as you push g/box along dowels rotate g/box output shaft and this will enable input shaft to engage with clutch driven plate. If it wont engage then probably driven plate not centered.

Roger

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18 Mar 2026 20:22 #264028 by Martin416
Replied by Martin416 on topic The last inch - Clutch change
Been a few years since had a clutch out. But from swapping boxes found bit of rotating while pushing usual gets there. As for alignment tool I feel last time I had tape round a extension for clutch side and some kind of weird head on the end that fitted into crank end 
SJ416 spi, 33s, Cage, Rocklobster

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18 Mar 2026 22:38 - 18 Mar 2026 22:39 #264029 by yakuza
Replied by yakuza on topic The last inch - Clutch change
Cant remember having problems with the SJ as I tend to romantisize.. but with the gen3 it is wiggle, wiggle, wiggle.
Once the ground cable was caught inbetween. And make sure the release bearing and clutch is in its place. And the correct clutch and no interference against the clutch arm. And check if there is no dowel in both the gearbox and the engine at the same position.

Had all these things happen to me.
Norway 2005 Jimny M16A VVT, 235 Cooper Disco, 2" Trailmaster, ARB rear lck.
Last edit: 18 Mar 2026 22:39 by yakuza.

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