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View Full Version : Help installing my clutch and new gears please


RockRunner
07-06-2010, 02:28 PM
I am off this Friday, July 9th. I am planing on replacing my clutch and 4.7 gears in my rear transfer case. I guess we will find out if UB and Jeremy were correct in stating that my gears 2.28 or not.

Any help is appreciated and I will be providing the appropriate items to keep your thirst and appetite at bay (don't want your concentration drifting away):thumb:

I live in Roxborough, South Littleton basically. So please let me know if you can help me get the Habanero back to its old self:D

PS any help is appreciated, even an extra set of eyes.

I will PM you my address if you can make it.

RockRunner
07-07-2010, 12:28 PM
Did I mention that I would provide beer and food:D

Come on somebody needs to be free............

Air Randy
07-07-2010, 01:53 PM
I'll be there on Saturday

RockRunner
07-07-2010, 02:20 PM
Awesome, now I won't have a tranny stuck on my chest ;)

RicardoJM
07-07-2010, 03:22 PM
I can swing by Friday after work to give a hand pulling the transmission and t-case. If things go well, we can probably get the clutch in. I've got swimming on Saturday morning. Do you have a tranny jack, air tools and a pilot bearing puller?

RockRunner
07-07-2010, 03:45 PM
Thanks Ricardo.

As for your questions;

No tranny jack I do have a rolling cart, we did not use one at Randy's place did we?

Some air tools. Are talking about using it on the 30mm bolt?

No Pilot bearing puller. Will have to get one from Checker

Anything else I need to get???

I do need some of that seam sealer and or Ultra gray stuff. I was supposed to get some but none came. Need to get with Scotty at Addicted.

RicardoJM
07-07-2010, 04:16 PM
Thanks Ricardo.
No tranny jack I do have a rolling cart, we did not use one at Randy's place did we?
We used a couple of jacks; one of them was a motorcycle/atv jack. A solid platform makes the load a bit more stable and easier to handle. The transmission and t-case is a long assembly as I recall.

Some air tools. Are talking about using it on the 30mm bolt?

While not a requirement, an impact and socket wrench are much nicer than breaker bars and undoing all the bolts by hand. :D

No Pilot bearing puller. Will have to get one from Checker

That would be good, or we could try the hydraulic method with grease and/or bread.


Anything else I need to get???

I do need some of that seam sealer and or Ultra gray stuff. I was supposed to get some but none came. Need to get with Scotty at Addicted.

Do you mean RTV? If so, you can pick up a tube at any auto parts shop; Permatex ultra black. Do you have new gaskets to replace any that get torn up on disassembly?

IIRC, the above covers the tools/equipment for dropping the tranny/t-case and getting the clutch in. I really was not close to the action on changing the gears, but I do recall there being some print outs with photos.

The clutch kit should have an alignment tool, if it does not I think the one I have from the FJ40 would work.

For the re-installation a torque wrench is nice, the end result is better than using the German spec of goodnandtight.:D

I've got some impact sockets in the sizes needed for the FJ40, and they might cover everything on the mini truck. I've also got torque wrenches.

I also recall a long set of socket extensions and wobble joint came in handy for the starter bolts and/or the upper transmission bolts . I've got the wobble joint but don't have the long extension.

If you can get a tranny jack, I think it would be nice to have on hand. I borrowed one from Teach2Fly but have since returned it.

Perhaps Randy and Issac can post up on anything we're missing that would be needed and or helpful.

Air Randy
07-07-2010, 04:24 PM
I think you have to press a gear off of the main shaft and press the new gear on to it. We didn't have to mess with that when we put the 4.70's in to my T-case because the guy I bought the gears from had bought an extra main shaft and had the gear installed on it already. I think. Be sure and check the instructions well for that step, I could be wrong.

TIMZTOY
07-07-2010, 05:12 PM
My shop has a flywheel resurfacer !!! The only one in Denver that I'm aware of ! Turning the flywheel is $35.00 plus my %20 discount. I also have a toque wrench and almost every thing you need for te job. Unfortunally i have to work both days 8-5 on Friday and 11-8 Saturday. If your sill working on it give me a call u have My # I'll see if my roomate has a motorcycle jack. Thats the easiest way.

J Kimmel
07-07-2010, 05:21 PM
wish I could help...24 Hours of LeMons is this weekend :D

Go Team Spidey!

RockRunner
07-07-2010, 05:35 PM
Thanks guys!

I have a motorcycle jack and will get the puller plus RVT the gray stuff is just special:rolleyes:

I have a torque wrench and impacts to get the bolts of so no hand tightening. Also I already have a clutch and pilot so we are good there. The biggest problem could be the pressing of the bearing.

I'll have to see what it calls for.

Not sure if I am going to make it to the meeting I hope so :beer:

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DaveInDenver
07-08-2010, 09:03 AM
B&B Machine near Evans & Santa Fe and Havana Machine Shop near Mississippi & Havana can face flywheels. I'm fairly certain Gunn Automotive can, too. Make sure they machine the step into the flywheel, factory IIRC says 0.020" but most people seem to be happier with 0.026". Havana does probably at least one Toyota mini (their delivery fleet is all 3rd gen 2WD trucks) flywheel a day, so they know what to do without much hassle. They also stock the locating pins if you need new ones.

I need to get my drivetrain back together and if I can get that done I have a scissor-type tranny jack that is current holding up my transmission. Stabbed a few 22R drivetrains and would like to help, but also working Friday and Saturday. I can offer to lend a hand Sunday, too.

You will need a 36" extension (whatever is the longest Sears stocks) for your socket wrench and a 19mm (or is 17mm?) swivel socket to get the top two bellhousing bolts. I have these, too, if you want them. Dean has an OTC pilot bearing puller that's been clearanced properly. I could not find mine last night, so not sure what happened to it. :-/ I've never had luck using the hydraulic method.

Uncle Ben
07-08-2010, 09:12 AM
Most all machine shops can do flywheels. Even NAPA can do them, some in house but all can send out to the warehouse.

RockRunner
07-08-2010, 09:22 AM
Thanks for the info guys, this is my first solo attempt at doing the whole set up. So I HAVE to resurface my flywheel before installing the clutch? All these details I forget about and or don't know.

Looks like I am going to start pulling things apart tonight so I can be set on Saturday when I get some help.

I don't have any swivel sockets but do have swivels I can put on my extension and socket, will that work? As for the puller, it sounds like I need to buy one and clearance it or borrow one right? I won't be able to get one from Checkers and use it as is?

Dave if there are any tools I can borrow from you to keep the cost down I would appreciate it. This breakdown came at an inopportune time, don't they all.

I don't have a tranny jack but I can use my motorcycle jack and make a cradle for it.

ANY OTHER ADVICE GUYS????????????? Please don't hold back.

RockRunner
07-08-2010, 09:28 AM
My shop has a flywheel resurface !!! The only one in Denver that I'm aware of ! Turning the flywheel is $35.00 plus my %20 discount. I also have a toque wrench and almost every thing you need for te job. Unfortunately i have to work both days 8-5 on Friday and 11-8 Saturday. If your sill working on it give me a call u have My # I'll see if my roommate has a motorcycle jack. That's the easiest way.


Tim, I may be stopping by and have you do my flywheel. Also if I need some tools can I go through you? How would we go about that? LMK please.

Got a Motorcycle jack.

DaveInDenver
07-08-2010, 09:37 AM
Surfacing the flywheel is not absolutely necessary if it's still flat and not glazed. Like if it was machined a couple of years ago and has not been 'wheeled hard... But it's only $30 or something and helps the clutch work better. IMVHO it's a no-brainer if the transmission is off already. But it's like brake discs and drums, there are only so many times you can machine them. Taking the flywheel off also lets you get eyes on the rear main seal to inspect.

You are of course welcome to whatever tools. I should not need the uber long extension, but might still need the swivel socket for putting my transfer back on. If you are still in need Sunday, I will bring a whole bunch of stuff down.

The pilot bearing puller is nothing special but my OTC had a few forging remnants that needed to be knocked off to fit easily in the hole. It's not extensive and it would probably would work fine with a bit of muscle (i.e. sorta BFH) since you are throwing the pilot bearing away anyway. I'm just obsessive-compulsive. If I can't find mine and you have to rent one from NAPA or Checker, it will probably be fine. If not, well, you know, who's to say anyone would notice if it saw a few seconds on a bench grinder and emory cloth?

RockRunner
07-08-2010, 09:43 AM
Thanks Dave, i think I should be fine then. If the puller is dragged across the "street by accident" well then what can I say.

I am going to start pulling things tonight and we'll see where that goes.

Red_Chili
07-08-2010, 02:18 PM
Heard lots of bad stories about not resurfacing the flywheel. Tend to agree on brakes unless we are talking the newer trucks.

DaveInDenver
07-08-2010, 02:51 PM
Heard lots of bad stories about not resurfacing the flywheel. Tend to agree on brakes unless we are talking the newer trucks.
I think there is a limit to how many times a flywheel can be machined but I can't tell you exactly why or how many. I suspect it's due to how much heat it can dissipate and not warp, crack or re-glaze. With brakes it's all about the amount of material from a heat aspect mostly rather than something like the travel of the hydraulics.

L43dean
07-08-2010, 02:53 PM
Tom, I have an OTC pilot bearing puller to fit, floor jack w/tranny adapter, 20" long 3/8" ext. and 14 plus 17 mm swivel sockets. All worked well to pull and install MC clutch and trans in both my pickups. OTC! POP and It's out. I can help friday evening and saturday too.

TIMZTOY
07-08-2010, 03:04 PM
Your welcome to my tools just swing on by park next to my truck and I should see u. But it looks like the guy b4 me has u pretty much covered. I dont care either way.

DaveInDenver
07-08-2010, 03:21 PM
the guy b4 me
Dean whilst we were reverse stabbing an engine back onto a tranny.

19721

RockRunner
07-08-2010, 04:05 PM
Tom, I have an OTC pilot bearing puller to fit, floor jack w/tranny adapter, 20" long 3/8" ext. and 14 plus 17 mm swivel sockets. All worked well to pull and install MC clutch and trans in both my pickups. OTC! POP and It's out. I can help friday evening and saturday too.

I would really appreciate it if you could help on Saturday. Friday I have to spend time with my wife ;) Where do you live? Maybe I can pickup the tools etc. in case I get that far on Friday afternoon.

L43dean
07-08-2010, 04:30 PM
hello Tom, I live in south aurora, near Cherry Creek state park. I will PM you this eve after work. threezerothreesixninethreetwoonezeronine. Dean

L43dean
07-08-2010, 04:46 PM
hey Dave, thanks for the awsome forumfoto! I would'nt let a guy who looks like that any where near my rig. However if'n you need a hand with re-assembly, please correspond. Dean.

L43dean
07-08-2010, 05:09 PM
wait till' you guys see who is on the cover of the next issue of "Bellhousing Quarterly"

DaveInDenver
07-08-2010, 05:19 PM
wait till' you guys see who is on the cover of the next issue of "Bellhousing Quarterly"
This fella with the chiseled features and obvious disdain of normalcy?

RockRunner
07-08-2010, 11:49 PM
Well she's torn apart now. Ricardo came over tonight and we tore into her. I had removed the drive shafts and was getting ready to drain the oil when he showed up. Nearly four hours later and we have everything out including the fly wheel. It looks fine but will still take it to Tim and have it resurfaced. The clutch was OK but could stand to be replaced since we are in there anyway.

Going to take the flywheel in tomorrow and start pulling the transfer case apart. I think that is about all I will get done before Sharon comes home and we have to go, 3:30/4:00.

I will have food and beer/pop for anybody that can help me, don't trust myself:o. Plus those dang parts are heavy;)...............oh and I need somebody to look over my shoulder to tell me when I am goofing something up like cutting the wrong part right Randy:rolleyes:

Sorry no pics we were working to hard :thumb:

RicardoJM
07-09-2010, 08:02 AM
All in all, the job went pretty smooth:D. The motorcycle jack and jack stands worked just fine.

I was thinking about a couple of things, while you are out and about today, you may want to pick up a bolt so that you can replace the stud at the top of the starter. While the stud makes it easier to put in a starter (you can just hang it on the stud) it gets in the way when sliding the transmission back.

Take your new pilot bearing and test fit it to the transmission. It should slide on, but sometimes it is tight and won't fit. IIRC on Randy's truck we hit it with emery cloth to get a good fit. If it fits, put it back in the box and toss it in the freezer; when you go to install it it will go in much easier. :thumb:

RockRunner
07-09-2010, 08:23 AM
Good ideas Ricardo:thumb: I will try the pilot bearing out and see how it fits. Also I should be able to find a 13 :rolleyes: to fit the starter stud :D:D

Also I will get all the oils/lube needed to fill her up so we can try her out when we are done.

I am posting up in the members section next to post my address.

Thanks again Ricardo:thumb::thumb:

RockRunner
07-10-2010, 10:12 AM
:d

J Kimmel
07-11-2010, 11:47 PM
I guess we will find out if UB and Jeremy were correct in stating that my gears 2.28 or not.





well, figure it out?

RockRunner
07-12-2010, 09:56 AM
Yep sure did. 2.28 in the front and rear:( Explains a lot but what can I say. The previous owner told me that was what was in there:mad:

Now at least I know for sure what gearing I have in the boxes and will enjoy it much more.:D

Still have to put everything together.:(

RockRunner
07-12-2010, 10:09 AM
So Saturday I started around 9 tearing the T case apart, that was the easy part:rolleyes:

Randy showed up a little while after that and installed the clutch while I was working on the T case, grinding out for the bigger gears. Around that time Steve Brady and Kevin Schlegel showed up, should have closed the garage door:rolleyes: They could not spend any money at the J**P show so they came over to make fun of us. Dean showed up around that time to and he brought the FSM with him, very useful. Ricardo showed to a little later and we ended up having a great little party. Some beer, read lots, a few pizza's and everybody was happy.

Went back to work after hanging on the deck and found an extra C clip:( We looked at all the directions and FSM but could not find where this clip had to go. Soooooooooooo her I am taking the case apart again to make sure I did not miss a clip anywhere.:mad: Case all apart and all clips accounted for:confused: Around that time most folks had to go home and I was tired and P :mad:

I would like to thank everyone that came over and helped me, especially Steve and Kevin :D They were the beer drinking humor department, thanks Steve I found out more info on Kevin than I really wanted too:lmao:. PS Kevin how did the Russian date go????:eek:

Dean took some pics hopefully he will post one or two up.

I am planning on finishing it up this week, case is together and now I need to string it all together.:thumb:

Dr. Schlegs
07-12-2010, 10:33 AM
She was not type. The high point of my day was you clarifying for your neighbor who you were talking to.

FJBRADY
07-12-2010, 10:49 AM
:ranger:I thought you needed help with your BEERS not your GEARS! My bad............:drink:

Air Randy
07-12-2010, 10:56 AM
Did you ever figure out where the extra C clip was supposed to go?

Dr. Schlegs
07-12-2010, 11:22 AM
:ranger:I thought you needed help with your BEERS not your GEARS! My bad............:drink:

:lmao:

J Kimmel
07-12-2010, 11:41 AM
Yep sure did. 2.28 in the front and rear:( Explains a lot but what can I say. The previous owner told me that was what was in there:mad:

Now at least I know for sure what gearing I have in the boxes and will enjoy it much more.:D

Still have to put everything together.:(

I figured as much...had to be!

You will notice a HUGE difference now when using double low. No more stalling :)

RockRunner
07-12-2010, 02:26 PM
Did you ever figure out where the extra C clip was supposed to go?

Nope, pulled it all apart, cleaned all the parts again and looked to see where they fit. Put each one with the part it clips onto and still had an extra.

I put it all together with both Marlin's and TG's instructions and never found a place for it. I have it all together now and it feels solid to me.

If anybody has any idea how many C clips go into a rear transfer case please speak up. Deans FSM only showed five and all my documentation shows five.:confused:

RockRunner
07-12-2010, 02:27 PM
I figured as much...had to be!

You will notice a HUGE difference now when using double low. No more stalling :)


I am sure I will.

Hey post up some pics of the race and how you guys did. They showed it on the news but did not see Spidy:(

RockRunner
07-12-2010, 02:28 PM
She was not type. The high point of my day was you clarifying for your neighbor who you were talking to.

Was she breathing and walking on her own??? And female to boot? What more do you want???? :lmao:

RockRunner
07-12-2010, 02:29 PM
:ranger:I thought you needed help with your BEERS not your GEARS! My bad............:drink:

I needed that beer to stay sane listening to you guys:blah::blah::blah: Bunch of jesters...............NOT :thumb::beer:

J Kimmel
07-12-2010, 06:10 PM
I am sure I will.

Hey post up some pics of the race and how you guys did. They showed it on the news but did not see Spidy:(

if you saw it on 9news, then you saw Spidey :D there was a short clip of the car on the track, and the clip with the booted car was us.

we finished 10th overall, and 6th in class, which is not too shabby for an untested car, and 5 of 6 drivers who have never competed before!

there were 58 or so cars entered in the race, and I would bet money there are at least 25% more cars next year, its that much fun. Figure about 4K for a first year team with all the expenses, and you will finish the race wondering when the next one is :D


/hijack off

RockRunner
07-12-2010, 07:14 PM
Sounds cool, we'll have to try and come by next year.

FJBRADY
07-12-2010, 07:45 PM
Was she breathing and walking on her own??? And female to boot? What more do you want???? :lmao:

I'm with Tom on this one....need to start Slump Busting!