Clutch Replacement tips, six speed 4x4.

So I had the dreaded squeak coming fro the TO bearing. I decided to take the challenge of replacing the clutch myself because I'm stubborn and more importantly CHEAP.
Here is a good video that really helped me get an idea of what I was getting into:http://youtu.be/kJBXW65Q2FU
Now I will list the issues I ran into that will save you time and frustration.
I also bought a used trans jack (harbor freight special) on Craigs list for $40. That really helped.
So after watching the video here are the tips I could have used.
First, Removing the shifter assembly. I broke mine by removing the extension and not the whole assembly. It's very simple. Remove the boots and cover from inside the vehicle. the very last dust boot (the smallest one) just peel it back and you'll see a ring with flat sides. You press it down and turn counter clock wise and it comes right out. I have attached some pictures. A Chilton's manual would have probably save me $130. Haha!

Second, remove both exhaust manifolds. They come out very fast and make it much easier to reach the top bolts on the bell housing. The gaskets are reusable, at least they worked fine for me.

Third, when replacing the rear main seal, and you should since you are there anyway. After installing the new seal in the housing plate. The side of the seal that the spring sits in, (the inside towards the motor) fill in with grease. It helps hold the spring in position while you are installing it back into the vehicle.

Finally, after removing the trans, I noticed the motor leaned forward and would make it hard to line up the trans when reinstalling. I used a motor cycle strap and pulled the motor back down.

Good luck, I hope this helps. I try to respond in a timely manner to any questions.

P.S. I installed a UDR Throw out bearing kit to avoid any future problems. I just bought this truck and I noticed the clutch was recently replaced. It was a brand new looking LUK. You need to either get the upgraded TSB parts from Toyota or the URD kit. Otherwise the bearing with go out within 10K miles. I decided to trust URD over Toyota. They should have recalled this problem.

 

I've read alot about the URD TO Bearing Kit being the real solution for the stock Toyo TO bearing kit. URD's Stainless steel sleeve vs. Toyo's aluminum sleeve...

Is there any data out there that shows the URD solution has much more longevity than the Toyota parts? i.e. have people had the URD TO installed for say, 3 or 5 years and not had the problem recurr?

 

I've had the URD set up for more than 5 years without issue. I don't believe I've ever heard of any problems with them at all.

Good write up OP. I put a bottle jack under the front of the motor before removing the trans to keep everything lined up. You can also get at the top two bellhousing bolts from the bottom with about two feet of extensions and a wobbly socket.

 

Fluffer, 5 years is good news! what year is your truck?