New91HrdBdy

Hello,

I am in the process of removing the transmission on my
2.4 liter 91 Hardbody 4x4 to install a new CenterForce II Clutch in it. Let me start off by saying that I have a fairly wide range of removal/installation experience working on "Cars" from transmission swaps to engine swaps to complete suspension setups. I felt pretty confident in my abilities to do this job but I quickly realized that this wasn't going to be; just another install!

I have never attempted a job of this nature on a 4WD truck and I am a bit confused as to what all components that I will need to remove in order to complete this task. I am working with a pretty lousey Haynes Repair Manual as my guide but this books details leave you wondering if someone at the store you bought it from ripped out the rest of the pages that contain the next steps.

My first question is if it's possible to remove the trans without the transfer case. If this is possible, is this the way to go about this task?

My next question is based on my theory that the trans can't be removed without the trasfer case. I notice that there are 2 Torsion bars that extend from the rear cross member all the way to the front of the truck which appear to also be the mounting location for the front control arms. It doesn't appear that these bars can be removed without getting into removing the entire front end of the truck at the sametime. I haven't been able to figure out how to remove this rear cross member without removing these bars at the sametime. From what I see it looks like this rear cross member will need to be removed in order gain the clearance that I will need to remove the transmission and the transfer case as one unit. Do these bars need to be removed to install a clutch in this truck? If these bars need to be removed, can they be removed without tearing appart the front suspension at the sametime?

What is the recomended procedure to remove these bars if all the above assumptions are true?

If the trans can be removed independantly of the transfer case then at what point on the trans should it be unbolted?

Sorry for all the questions, but I think I may have opened a can of worms that I didn't realy want to get involved in.

Thanks for any help you can provide!

jadcock

Simply replacing the clutch on one of these trucks just doesn't come "simply", as you're finding out. The torsion bars attach to the front control arms, but don't actually "mount" them. So you can remove them independent of the suspension. The correct procedure (someone correct if I am wrong) would be to remove as much pre-load as possible from the torsion bars by jacking up the front of the truck, loosening the bolt on the torsion bar adjuster (see pictures for more details), and ultimately removing the adjuster and torsion bars. Then you can drop the crossmember to remove the transmission/transfer case assembly.

__________________
Jason Adcock
Always Tread Lightly!
1995 4x4 XE King Cab - 189,000 miles
1997 Cadillac Seville - 141,000 miles

New91HrdBdy

This is good news about not having to remove the front suspension for sure.

So from what it sounds like, loosening those bolts that are rusted to hell located on the Top of the rear cross member will somehow cause the Torsion Bar to "sag" so to speak; at which time you can then "Strong Arm" it out of it's location once all the bolts are loosened. Do the Frames on these trucks have that much stretch or flex in them to allow for this bar to be almost separated from their location by simply jacking up the front? If only the front of the truck was on ramps (which it is) would this suffice verses jacking it up or do the wheels need to be hanging unsupported while the front is in the air.

Your input is very much appreciated and I hope to hear from others as well on any secrets or short cuts they use to do this job.

Thanks Again!