Greetings all!
Let me first say thank you to all you knuckle busting fender jockeys that make this a great place to get info! <img src="/forums/images/graemlins/smile.gif" alt="" /> I have not had my Trooper too long and its only my second import so its really nice to have access to all of this knowledge.
I have been reading through past postings about clutch replcement and i need an honest answer from you.
My only experience with replacing clutches is on 2wd F-150's. My Trooper is a daily driver so down time is an issue. I have helpers available and willing that have import front wheel drive exp. A garage with multiple floor jacks and stands, basic hand tools (no air). I know that I can most likely handle this clutch replacement skill wise, but... My biggest concern is, after reading posts--the transfer case aspect of this job. Not having worked on 4wd how different is this than 2wd or front wd? Would it be worth it to have a shop do this for me <img src="/forums/images/graemlins/baby.gif" alt="" />?
Or do I start Friday night and hope for the best before Monday morning?

Thanks

Home or away single choice
	do it --home
	shop it out
Votes accepted starting: 06/21/10 03:47 PM
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The transfer case doesn't really come into play. It just hangs on the back of the tranny.

In my opinion, you will need a true tranny jack, from a rental yard. I would get a 1000 lb. rated one. The tranny/tcase isn't that heavy but you need the reach of a big tranny jack, particularly since you will have the rig on jack stands, preferrably the six ton truck size.

Also, don't try to save a few bucks by not draining the tcase and tranny.
Basically, you remove The shifters and the various shields, remove two drive shafts (rather than one on a 2WD), remove the middle portions of the exhaust system, then upbolt the tranny from the engine. The top bellhousing bolts can be a pain to get out, but a 24" and a 12" extension, or better yet, a 36" extension make it doable. You will also need to disconnect 1 or more switches, depending on the options you have. You will also need to disconnect the clutch slave cylinder.

A trick I learned from Curtis Johnson is to run a short ratchet strap around the tranny and then connect a large ratchet strap to the the first strap and the other end around your rear axle and then crank on the ratchet. The tranny will pop right loose if everything is disconnected.

I have had mine in several times in the last couple of years and I have made most every mistake I can think of.

I used a combination of rachet straps and a regular large floor jack to drop my trans and put it back in on my truck.. I can't say it was the easiest tasks being the attached trans and tcase..