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Discussion Starter #1
Hi - I've done a ton of searching and found a lot of good info on symptom, pros/cons of conversion, kit selection, etc.

I am hoping to find info (or a link to previous threads that I couldn't find) on:

- Has anyone done a 'tech writeup' on clutch replacement / flywheel conversion

- Do any of the kits come with really good 'how to' instructions for do it yourselfer

- Are there any specialized tools that might need to rent or buy to complete this (tranny jack?)

Thanks
 

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Rangers Lead The Way!
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11,655 Posts
you are in luck sir as i just did this swap a week ago

There is no need for a write up as its a bolt in replacement, no tricks or changes at all. unbolt old flywheel. bolt on new one.

I am not sure what you need for instructions but i could talk you through the entire thing

and a tranny jack makes life so much easier BUT being a zf5 is flat bottomed for the most part you could make way with a heavy floor jack
 

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Discussion Starter #3
Hey thanks for replying!

Does the tranny need to be removed? I thought it did (and if so I've never done that).

Could you give a little more detail on how/what you did?

Also, I've been searching / reading a lot and have heard how replacing that turbo downpipe is a good thing to do. Do you agree and/or anything else I should consider doing at same time?
 

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Rangers Lead The Way!
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yeah tranny has to at least slide back but pulling it out is so much easier

Ok here is how i did it (my expierience will differ from yours a bit) also mines a 4x4 so if it doesnt apply dont worry

Drop exhaust (if stock remove at the Cat)
remove rear driveshaft
remove front driveshaft
undo transfer case shift linkage (use pry bar on t case side of linkage)
unplug T case wiring
remove transfer case
go to top of the truck and remove shifter boot then shifter
back under the truck loosen up then push out transfer case shifter
remove reverse sensor wiring then move wiring harness aside
support transmission then remove crossmember

At this time you have some choices. you can disconnect the clutch line at the clutch master cylinder OR disconnect it at the master cylinder up by the brake booster (i did the master cylinder so i wouldnt have to rebleed the system much)

remove Bellhousing bolts

now if you can slowly wiggle the trans back and lower it as you do ( I had to pull my carpet back and removed the trans cover in the floor to make room. Some people do some people dont. just be prepared to maybe have to

now with the trans out of the way undo the pressure plate, undo the flywheel

bolt on new ones using provided torque specs and using the alignment tool

reinstall trans and hook everything back up
 
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