I'm pulling my tranny out to have it rebuilt, and want to replace my clutch while the tranny is out. Can anybody tell me step by step how to do it? Thanks in advance for any advice.

 

Drop the drive shafts, Put a jack and blocks on the engines oil pan to support it.,Remove the cross member [helps to spread the frame rails]., Remove the 4wd shifter, Remove the transfer case, Remove the shift ***** and boot, Remove the shift handle, Remove the CAD vacuum lines, Remove the transmission, Remove the clutch slave cylinder, Remove the bellhousing, Remove the clutch. There are minor items like the vacuum lined going to the transfer case and speedometer semsor ect. Just look a bit before you act. You will need a good transmission jack as it is heavy. I prefer to remove the transfer case from the transmission but you can leave it attached. Just be carefull because it could hurt you badly if you are careless.

 

Remove the transfer case. It makes going back in with the tranny a whole lot easier.

 

That cross member is a PIA.
CJ

 

definitely hae a porta-power on hand for putting the cross member back in...you really have to spread the frame rails or you'll never get it back in

...and I left the transfer case attached to the tranny when I did mine...just use a good tranmission jack and a strap around the tranny

...make sure to turn the flywheel or have it done at a diesel shop, because there's not much point to a new clutch if it still doesn't have anything to grab on to...2 cents...

another thing...it's cheap insurance to replace the rear main seal while you're in there and have everything out of the way...they are kind of notorious on these motors to go out...