by andy120 » Sat Jun 25, 2016 5:51 pm
Ok, day 1. Chronological order. Auto selector removed. 4 screws from handbrake console (to uncover rear two screws of selector surround). 4 screws in that surround. 4 bolts and 2 screws in the plate under the selector. Disconnect the brake interlock, 1 nut and clevis like thing. Remove the 4WD selector stick, 2 bolts. R-clip off the bottom of the selector. Front jacked onto stands. Put a jack under the back of the gearbox somewhere, the cross member has to come off, 4 bolts a side + 2 14mm nuts on the mount. Move the selector on the gearbox the neutral, 3rd click from the back. Driveshafts off. All bar one bolt came off easy. The last was persuaded with cold chisel. You need to turn a wheel to rotate the universals to get at all the bolts. Bolt holding the oil cooler pipes and remove rubber hoses. We just hacked the pipes of at the gearbox end fittings. Drop the back end of the gearbox, this uncovers the bell housing top bolts. You can get at them with a heap of socket extensions thru the selector hole. Mirror and torch required. Unplug what you can (we chopped anything not cooperating) Starter motor and the other bell bolts. Remove screws from the small plate under the flywheel. 6 bolts in there from torque converter, lever the flywheel around to get them. Now the fun part. My exhaust has no flanges where it passes right to left. We let go what ever exhaust mounts we could for wiggle room. Put a jack under the motor sump and one under the gearbox front. There is a pin in the top of the bell housing what is a pain. We tied a strop around the rear flange and pulled back while crow baring the join and getting the transfer case over the exhaust and cross member. We had 3 people for this bit. That pin kept getting stuck on the flywheel. Eventually the schizer came out and dropped it onto the ground off the jacks and dragged it out. Flywheel removed and manual one went on and clutch installed. Pull out the 3 groups of wires from the gearbox. On the passenger side there is a bracket holding 3 plugs, the 2 nuts are nicely accessible in the wheel arch. We broke the clutch hard line at the bleed block. Feed the upper hard line down and reattach it to the bleed block. Mine has a second battery position making things more difficult. The block bolts thru where the bracket was. The bottom hard/flex join bolts to a small bracket right in front of you if you are sitting in the tunnel. At this point we gave up for the night soaked thru (outside in the rain with leaky tarps). ~7 hours. Probably missed a few things.