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MadMax
08-01-2009, 02:56 PM
Doing a clutch replacement on a TS 2.6L manual. Lots of things have been stripped off so far, but I'm struggling with a few things. (First time job)

(1) Trying to move the wiring harness that runs over the top of the front of the gearbox so it doesnt get damaged - the oil pressure switch has a cover over it, made of metal or hardened plastic. How do I disconnect the wire?

(2) Need to remove the passenger side transfer shaft - gearbox to support bearing - but I can't get to the bolts on the back of the block. To get to it, I'm trying to remove the starter motor, but it jams up against a support bracket. How do I remove the starter motor?

While I'm here - the clutch was working fine, until suddenly (I wasn't driving) the clutch started to slip. It is so bad that in 1st gear the car won't move at all, need to start off in second - with lots of slip! I suspect pressure plate failure - anyone experience this?

[TUFFTR]
08-01-2009, 03:13 PM
Doing a clutch replacement on a TS 2.6L manual. Lots of things have been stripped off so far, but I'm struggling with a few things. (First time job)

(1) Trying to move the wiring harness that runs over the top of the front of the gearbox so it doesnt get damaged - the oil pressure switch has a cover over it, made of metal or hardened plastic. How do I disconnect the wire?

(2) Need to remove the passenger side transfer shaft - gearbox to support bearing - but I can't get to the bolts on the back of the block. To get to it, I'm trying to remove the starter motor, but it jams up against a support bracket. How do I remove the starter motor?

While I'm here - the clutch was working fine, until suddenly (I wasn't driving) the clutch started to slip. It is so bad that in 1st gear the car won't move at all, need to start off in second - with lots of slip! I suspect pressure plate failure - anyone experience this?

Just yank the wire off the end of the oil pressure sender (Im going off a 3L but cant be much different) If not, chop it off, and crimp on another terminal later on.

Cant help on the transfer shaft question, is it a simple case of using an extension and/or uni joint?

MadMax
08-01-2009, 04:00 PM
Fair enough.
Gotta be able to see where to point the socket though!
Will have another look with a torch when its dark.

update: got the sleeve off the oil pressure switch - its rubber but much hardened. I need more lift on the front end of the car so I can get to those bolts at the back of the engine - tomorrow will do. I'm keen to find out why the clutch failed - has only done 217,000 Km -should be hardly worn! lol Exidy clutch ready to go in, if the flywheel is ok. (somehow I doubt it)

MadMax
10-01-2009, 11:28 AM
mess! Just wear and tear . . . A new clutch plate is 9.5 mm thick, this one is 5mm.

[TUFFTR]
10-01-2009, 11:31 AM
mess! Just wear and tear . . . A new clutch plate is 9.5 mm thick, this one is 5mm.
For 217K's you got your moneys worth!

MadMax
10-01-2009, 11:36 AM
Funny thing is, the rivets are showing on the pressure plate side and have chewed it up, but the flywheel side is much better - flywheel has no marks on it!

What I've learnt is ---
(1) mechanics sure earn their money!
(2) next time - bonnet off, engine and gearbox out in one unit - so much easier!