Samurai SJ413 clutch swap UPDATED

Starts at the flywheel, ends at the hubs, any problems along them lines, ask your questions here.
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Jordi
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Samurai SJ413 clutch swap UPDATED

Post by Jordi » Fri Apr 19, 2013 1:03 am

Under the bonnet
Disconnect the battery
Remove the starter. It has two bolts, one has a thick wire attached to it, this os easiest to get to from underneath. It also has one wire clipped on and one bolted on. There are easiest accessed from the engine bay.

Inside
Unscrew the gear knob and unbolt and remove the gaitor
Unbolt and remove gear lever (not neccessary but can make it easier)

Underneath
Drain gearbox oil (not neccessary, makes it lighter, prevents spillage, when was it last changed?)
Unclip the reverse light wire from the loom. Its on a plastic plug.
Remove the crud guard off the front of the gear box 2 x 10mm bolts
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Remove the front cross member
Remove the gearbox to t/box propshaft
Undo the clutch cable from the arm
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Support the rear of the engine under the sump on a jack, its also advised to put a block behind the distributor wedged against the bulkhead so it doesn't bash about when the gear box drops off.

Unbolt the rear gear box mount (back of the gearbox, funny shaped rubber mount)
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Now undo the gearbox to engine bolts
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Easy stuff done.

Now you need to push the gearbox back to free it off the engine. I find it easiest to put the back towards the passenger rear and jiggle it till it comes through between drivers footwell and engine. Its out.

UPDATED BIT:- When you remove the box it might pull the two sleeves off the engine. These are two small cylinders approx 25mm x 13mm. Watch for them possibly dropping out. They are just a push fit back into two whole where the bolts go. Should be a tight fit but push in by hand DO NOT HIT WITH A HAMMER!

Remove old clutch. Bolts will be tight, just hold the ratchet firmly in place and bash the handle with your hand and it'll free them with out the fly wheel spinning.
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New clutch in.

Tighten it up so you can just waggle the disc. Using a clutch alignment tool centre it to the pilot bearing and torque up the plate.
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On the gearbox
Remove the clutch release bearing. It's held on a pin on one side. It just twists and drops off, replace this with a new bearing. They usually come pre greased but i always add more making sure in forced right into the bearing.

Force the gearbox back in and find a friend!

I found it a bitch to get the box back on as the spline weren't lining up. While one hold and jiggles the gearbox onto the engine the other needs to slowly turn the flywheel with a screw driver till the box slides upto the engine. The quickly bolt it to the engine as its still full of oil and gets heavy when you've held it a while.

Bolt everything else up and adjust it.

Bit iffy but almost complete. I'll tidy it up when i'm home and add photos.
Last edited by Jordi on Fri May 31, 2013 8:59 am, edited 5 times in total.
1988 Samurai - Truck Cab & Tray Back - 1.6 8v & HIF44 - Snorkel - Stack Exhaust - PAS, YJs & 33s - Trussed, Gusseted & Pumpkin Capped Axles - 4.3 R&Ps - 4.16 T/Box - Rear Air Locker - Full Float Back Axle & Discs - RCV Front Shafts - X-Eng Handbrake - Custom Fuel Tank

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Jordi
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Re: Samurai SJ clutch swap

Post by Jordi » Fri Apr 19, 2013 1:14 am

Luckily i have a spare engine, clutch and gearbox for a photo shoot. I'm quite excited. I might even get it stickied if i do a good job.
1988 Samurai - Truck Cab & Tray Back - 1.6 8v & HIF44 - Snorkel - Stack Exhaust - PAS, YJs & 33s - Trussed, Gusseted & Pumpkin Capped Axles - 4.3 R&Ps - 4.16 T/Box - Rear Air Locker - Full Float Back Axle & Discs - RCV Front Shafts - X-Eng Handbrake - Custom Fuel Tank

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Re: Samurai SJ413 clutch swap

Post by kiwizook » Fri Apr 19, 2013 6:31 am

I like the effort Jordi, we need more guys like you :thumbup:
It's not a question of how much you spend on your suzuki, but when your money will run out

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OllieSJ
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Re: Samurai SJ413 clutch swap

Post by OllieSJ » Fri Apr 19, 2013 8:02 am

:thumbup:
Sj410Q- Spacers, Bucket seats, Su carb , Mot and Tax

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Jordi
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Re: Samurai SJ413 clutch swap UPDATED

Post by Jordi » Fri Apr 19, 2013 10:07 am

Don't know if this makes sense. But....

It's an easy job to do. Just a few nuts and bolts. But its a chew on. I cannot change a clutch with out bruising and bleeding.

If you have or can get ramps to sit it on for extra room under it helps a lot.

At times it need patience and a gentle touch. Also requires the usual brute force and ignorace too.
1988 Samurai - Truck Cab & Tray Back - 1.6 8v & HIF44 - Snorkel - Stack Exhaust - PAS, YJs & 33s - Trussed, Gusseted & Pumpkin Capped Axles - 4.3 R&Ps - 4.16 T/Box - Rear Air Locker - Full Float Back Axle & Discs - RCV Front Shafts - X-Eng Handbrake - Custom Fuel Tank

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Jordi
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Re: Samurai SJ413 clutch swap UPDATED

Post by Jordi » Fri Apr 19, 2013 11:30 am

Cheers lads. Its not a complete how to just yet but was all done on the phone at approx 1 o'clock this morning. Not bad seen as i was up at 6 yesterday morning and again at 6 this morning.

Just a shame i didn't have a set of photos i could have put straight up.

I'm going to try and make it an idiots guide (no offence intended) with nut and bolt sizes and tools required.

It will be good enough for a stickie!
1988 Samurai - Truck Cab & Tray Back - 1.6 8v & HIF44 - Snorkel - Stack Exhaust - PAS, YJs & 33s - Trussed, Gusseted & Pumpkin Capped Axles - 4.3 R&Ps - 4.16 T/Box - Rear Air Locker - Full Float Back Axle & Discs - RCV Front Shafts - X-Eng Handbrake - Custom Fuel Tank

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ScottieJ
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Re: Samurai SJ413 clutch swap UPDATED

Post by ScottieJ » Fri Apr 19, 2013 12:33 pm

If you make it good enough i'll turn it into a write up in the DIY section :thumbup:
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Jordi
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Re: Samurai SJ413 clutch swap UPDATED

Post by Jordi » Fri Apr 19, 2013 12:34 pm

Dunno if it can be that good. I new i should have taken more photos when i did it.
1988 Samurai - Truck Cab & Tray Back - 1.6 8v & HIF44 - Snorkel - Stack Exhaust - PAS, YJs & 33s - Trussed, Gusseted & Pumpkin Capped Axles - 4.3 R&Ps - 4.16 T/Box - Rear Air Locker - Full Float Back Axle & Discs - RCV Front Shafts - X-Eng Handbrake - Custom Fuel Tank

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ScottieJ
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Re: Samurai SJ413 clutch swap UPDATED

Post by ScottieJ » Fri Apr 19, 2013 12:43 pm

Jordi wrote:Dunno if it can be that good. I new i should have taken more photos when i did it.
Its only about an hour job so do it again :lol: I've got to do karis's but as we're rebuilding an engine to go in we'll be doing the clutch at the same time so i could do an engine out version as well.
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Re: Samurai SJ413 clutch swap UPDATED

Post by OllieSJ » Fri Apr 19, 2013 12:45 pm

Jordi wrote:Dunno if it can be that good. I new i should have taken more photos when i did it.
But you are a pro at english ;)
Sj410Q- Spacers, Bucket seats, Su carb , Mot and Tax

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