I will be replacing my 92 4X4 clutch soon. I have never done one and am looking for advice. I will be using the LUK Pro Gold 12.25 in. Any helpful how-tos or advice would be apreciated. Can I use the stock flywheel with the smaller clutch? Should I replace the flywheel or have the old one machined ( or even bother)? Do I need to replace anything else why I am there? Master cyl, slave cyl, rear main seal, cam plug seal?

 

Yep, while the truck is raised and the trans. is out it is the easiest time to do several things. Replace the pilot bearing in the center of the flywheel. replace the throwout bearing. Replace leaking seals. Check the flywheel for heat stress signs, that is blue or purple shading, flaking, fine cracks, and warping. The flywheel can be resurfaced by a machine shop just like brake rotors are done. I would chose a stock cluch from mopar. The harder grabing cluches and brake pads (performance) usually have a shorter life span than stock units, but thats just my preference. The specialty tools are a pilot bearing puller and a clutch centering tool, they are must haves even if rented. Check the cluch fingers and springs for damage. Tighten the clutch in progressive steps. A transmission jack is really helpful, probably required. The cylinders can be rebuilt or replaced if neccessary. IF this truck is being used in competition all the stuff should be replaced with new heavy duty units. In drag racing a scatter shield is used in case of transmission blowups, but I have not seen these used in off roading. Speaking of safety, use jack stands and not just the jack. Chock the wheels. I do my own repairs, especially brakes. If you want something done right you've got to do it yourself.

 

First, park your truck in a nice heated garage on good cement and make sure the refridge is stocked with beer for your friends. Next get a good tranny jack to support the trans and T-case as an assembly and secure it to the jack. If you can't get a good jack you will have to remove the T-case seperately then the trans. Best to get a repair manual for all the steps for removal.
A few tips that are not in the book. Check the pilot on the input shaft for scoring or irregularity. Replace it if anything looks wrong. Check the splines for wear. Reface the flywheel if it shows grooving or heat cracking. If the cracks are deep, replace it. Use some good hi temp grease in the pilot bearing. Hi temp wheel bearing grease works good there. Don't use too much as it will get on the clutch while driving. The clutch kit should come with an alignment tool, make sure it slides in and out easily with NO binding. Use locktite on the flywheel bolts and pressure plate bolts. Look up the torque specs for the bolts. I don't remember it.
While you have the flywheel off check for oil leaks on the rear main or anywhere on the rear of the rear of the motor and repair as necessary. If there are NO leaks don't try to fix it. I don't know if the smaller clutch is compatible with the flywheel. If you ordered it for this application it probably will work. If it takes a different flywheel normally the parts man will tell you when you purchase it. I'm sure others on this site will chime in to answer this. Don't forget to use a jack under the rear of the motor to support it because it is very heavy and won't balance. Use good safety stands to support the truck in the air. Good luck

 

Do I need any special tools to pull the flywheel? I think the kit comes with an alignment tool. Any other advice? I know many clutches have been replaced out there. I don't have a transmission jack. Can it be done with a floor jack or motorcycle jack and a few extra hands or should i rent one?

 

The flywheel is just bolted on with about 8 bolts. Careful when you undo the last bolt, she's a heavy one.
Here's the things I do on every clutch job:
-flywheel gets machined
-rear main seal gets replaced (it would sure suck if it leaked all over your new clutch in 1 month)
-pilot bearing/bushing gets replaced
-trans input shaft gets replaced if pilot scored badly from bushing failure
-transfer case gets removed from trans. (just too awkward when attached. Each component is 200lbs and you're laying under it)
-any other driveline leak, bad u-joint etc. gets dealt with, since it is already apart.

 

On the subject of resurfacing the flywheel, get a new one if there are any heat cracks. You do not know how deep they go and after resurfacing you do not know if any are still there due to the surface finish from the grinding process. If used with cracks still in there they will act like little razors shaving away at your friction material shortening clutch life.
Go to the hardware store and get 2-4 bolts the same size as the bellhousing bolts but as long as possible. Cut the heads off and grind that end to a taper. Hand thread these into the block (loosely) to act as guide pins when sliding the trans back in. Good luck

 

I'm just wondering if anyone knows what a new flywheel cost???? After market????

Robert

 

I just finished installing a new clutch this weekend. I went with the Pro-Gold unit. COmes with everything, new PP bolts, bushing, TO bearing and alignment tool.

I liked the Pro-Gold disk material better, the SBC unit seemed a bit lighter material in the PP hub.

Be sure to lightly grease the nose shaft and the T/O bering collar.

 

I did mine two months ago and I rented a transmission jack it made the job alot easyer, faster and safer.

 

Some kits come with a needle type pilot bearing as well as a bronze bushing. Do not use the needle bearing because it can and will wear into the input shaft as more miles are put on the truck. Like torquefan, I suggest you resurface the flywheel after you look it over real good for any signs of heat, cracks etc. This should run around 20 bucks give or take.

 

Auto Zone has a flywheel for 44.99 plus 130.00 core. Seems like it may be better to just replace it. Are all flywheels created equal? They have the LuK Pro Gold for 409.00. I have seen it on the internet for 325.00 plus shipping. Anybody seen a better deal? Do you guys separate the transfer cas from the trannny or remove them together?