TD gearbox removal

[2000 XJ]

Hi Guys

There is some great info here!

I have taken my gearbox out to do these seals on the block, been ok so far with the transmission attachment on my 2ton jack. The gear lever was tricky until I realised how it works! You need two m6 bolts with nuts and washers to spread the two halves of the clamp apart! Easy when you know how.
Those two top bolts! Why did they use those stupid heads! A 10mm 6 sided socket on two extensions will do it. Replace the bolts!

My Jeep has 180k on the clock and I found the clutch and flywheel still in good condition surprisingly!

Welded up a bracket to hold the flywheel while undoing the bolts.

Finally got to the adapter housing, should be easy from here!

There seems to be a lot of end float of the crank but the thrust washers don’t seem worn? I’ll have to put the flywheel back and measure it with a dti

Anyone shimmed the thrust washers or replaced them?

Cheers Andrew

[amlav]

When I did mine could not source out the half trust washers anywhere .
So just cleaned and polished the surfaces up and plonk them back . Still no funny clonking noises so far .

[arotovegan]

I had a mechanic change out the clutch and do the rear main seal for me at one point. He forgot to put the thrush washers back in so I had to take out the tranny again with a mate. The mechanic wouldn't admit that he'd made a mistake and reckoned he couldn't find the thrush washers so I had to get some new ones. Managed to get some from Transdiesel Ltd here in NZ. They're the VM distributor in NZ. I think I got all three sizes for $150. Only ended up needing the standard sized ones though.

I see there are a few on ebay but I don't see any oversized ones. Maybe try LK diesel services if you are in Aus. I could probably find the numbers for the proper end float range if that would be helpful.

[amlav]

Thanks for the info . Didn't know they come in different sizes . How did you find out that your mechanic mist putting the trust washers back ?
Cheers Andrei

[arotovegan]

It was making a rattling noise when it was in neutral and my foot was off the clutch. I found a video where a guy had the same issue with his XJ, I managed to contact him and he told me what he had figured out. Given the work I had just had done, it seemed likely that I had the same issue. Made it a bit quieter (and stopped my crankshaft moving around) but it also turned out that the wrong clutch was put in. That was my fault since I got the parts for the mechanic. The clutch kit was actually one off ebay that a guy on here recommended. Problem was that it was designed for petrol engines so it wouldn't dampen the diesel vibrations enough for the gearbox.

Yup three sizes so you can adjust how much crankshaft end float you have.