 |
|
WWII Willys or Ford G503 Clutch Replacement. |
| 8/22/2008 This article is based on Ronnie Guin's recent clutch replacement. We have some pictures, but some we do not. Be sure not to stretch or damage any lines, brackets, hoses, or wires as you must tilt the back of the engine down. Pull all of it (Transmission, Transfer case, bellhousing, crossmember, and clutch tube) from the engine as one unit. 
|
| 8/22/2008 Jack the jeep up until you have all four tires about 5 inches off the floor. Placed Jeep on four jack stands, two under each axle. This gives you plenty of room to put the transmission jack under it. You will need the extra room when you pull the unit out and roll it back out of your way.
|
| 8/22/2008 Use a large rolling floor jack under the engine.
|
| 8/22/2008 loosened the top radiator hose clamp. This hose will slide back about 1 1/2 inches while lowering the engine. Put a rag under the hose because it will drip some.
|
| 8/22/2008 Disconnect the battery cables, the wire from the coil to firewall, gas pedal linkage, speedo cable, emergency brake cable, fuel line to passenger fender, removed air filter, removed stay cable, brake pedal spring and skinny top linkage to tube, disconnected ground straps on top of engine and top of transmission to bottom side of tub. Loosen both 3/4 motor mount nuts (engine pivots back on these) and be sure the manual priming handle on the bottom of you fuel pump is pulled up and out of the way. You do not want to bend it as the engine is tilted back. Disconnect and remove the starter. 
|
8/22/2008 Disconnect the wire from the coil to firewall,
|
| 8/22/2008 Disconnect gas pedal linkage
|
| 8/22/2008 Disconnect speedo cable
|
| 8/22/2008 Disconnect emergency brake cable
|
8/22/2008 Disconnect fuel line to passenger fender. This picture shows a late model version of this line. The early model has the fuel line going across the engine to the fuel strainer.
|
8/22/2008 Removed air filter
|
| 8/22/2008 Disconnected ground straps on top of engine and top of transmission to bottom side of tub. This picture shows the bottom transmission ground strap, there is another one on the top part of this area. 
|
8/22/2008 Remove the engine Stay Cable. It connects from the engine to the transmission crossmember
|
| 8/22/2008 Loosen both 3/4 motor mount nuts (engine pivots back on these) and be sure the manual priming handle on the bottom of you fuel pump is pulled up and out of the way. You do not want to bend it as the engine is tilted back. Disconnect and remove the starter.
|
8/22/2008 Disconntect brake pedal spring and skinny top linkage to tube
|
| 8/22/2008 The most difficult part is with the top bolt just below the gas pedal linkage. There is very little room to work so to get these bolts loosed off you can use an angle socket.
|
8/22/2008 Remove starter
|
| 8/22/2008 Take skid plate off, then muffler at the tub floor only and slide it out of the way. Take u-joints loose at each axle and pull them with the unit.
|
| 8/22/2008 Remove transmission hump covers and Take all shift levers loose.
|
| 8/22/2008 Put a jack under the jeep with piece of carpet and a block of one by wood to balance and keep anything from sliding. Removed nuts and bolts from transmission cross member as well as the bellhousing to engine nuts and bolts.
|
| 8/22/2008 Put a small set of vise grips on the clutch cable and againist the bellhousing. This will keep the fork and cable from coming loose when you pull the unit.
|
| 8/22/2008 Take the two bolts that hold the clutch tube to the frame ball bracket. The tube and bracket stayed on the transfer case the whole time as I carefully pulled the unit back and lowered the unit and engine.
|
| 8/22/2008 Carefully lower the unit and engine with both jacks. Do it slowly and kept checking for any obstructions that I might have overlooked.
|
| 8/22/2008 Using screwdrivers pry the unit away from the engine sliding it back out for the way and changed out my clutch. Besure that you place the clutch plate on the correct side. There is a marking on the plate. 
|
8/22/2008 Inspect the throughout bearing and spring while you are at this point.
|
| 8/22/2008 Also, you can align the clutch and clutch plate with an old transmission gear that goes into the drive shaft Put back together Reverse order and slide the unit back and began bolting it together. Be sure before lifting the engine back up that you get to the hardest nuts and bolt in first on the top of the bellhousing. 
|