For me, it's been nearly two years. Distraction after distraction has kept me from getting my clutch and transmission back in.
The bad things about the length of time I have let lapse:
I forgot how a lot of the linkages go together and what bolts go where.
Luckily, I was smart enough to put everything in ziplock bags and clearly label them, so it should be fairly simple to figure it out.
Transmission and transfer case go in tomorrow, get their fluids changed. I'm not going to say that I'll have it running and driving tomorrow, but I hope that will happen this week.
Funny story that got me back under my Jeep is that I finally got enough money to put into the rear end of my pickup to take some crap to the dump, so it's in the shop as we speak. My roommate tells me he enlisted in the Army and he needed some money to pay off a fine, then offers me his '03 TJ for a grand. I'd have been an idiot to pass it up so I bought it. Now I have far too many vehicles for my own good and have to sell something. I was thinking of offing my CJ, but now I think I'll axe the truck.
I love my Jeep too damn much.
1986 CJ7, 4.2L I6, Carter BBD, Rancho 2.5" Lift, Team Rush.
Coming soon: Exhaust, Wheels and Tires, Axle Gearing.
I changed the clutch in my cj5, total time probably 5 or 6 hours. I spread that over a few days. I had to have the flywheel re-surfaced, took a day for that. Make sure all of your new parts are what you need before you put it back together. The pilot bushing that came in my kit was not the correct one. It was too small for the input shaft on the transmission. Probably lost an hour or so messing with that. Experience is the greatest teacher.
I last did mine in the driveway in an ice storm. A couple other Jeepers showed up at 6:00 AM after I got off work and we used a handy shade tree for a hand winch to pull the engine out to do the clutch from the front. We were done before lunch.
Make sure you get the correct fluids in your T5 and Dana 300, they don't take the same stuff. Well, they 'can' both take the same stuff but.
The T5 needs a GL3 or GL4 rated gear oil so the syncros don't get harmed which is hard to find. The Dana 300 has no syncros so it can use the more common GL5 rated fluid, same as the differentials use.
Napa sells this gear oil that works: SAE 85w90 Gear Oil GL4 (also meets GL3), Part #SL24239.
86/00 CJ7 Laredo, 33x9.5 BFG AT's, 'glass nose to tail in '00, 'New' frame,wires and plumbing in '09. Carter BBD Carbed 4.0 HO in '10.
89 YJ Renegade. BBD Carbed 4.0 HO. Locked front and rear with 33x9.5 BFG AT's
Some Canadian Bush Jeep Runs and Build Photos: http://mikeromainjeeptrips.shutterfly.com (10 new albums added Sept 16/10)
I spanned mine out into about 4 days. This included opening the t4 and d300 for inspection and flushing out both of them before installing and resurfacing the flywheel. The alignment of the clutch with the tool was the hard part. I put it on a little off center and I had to re bolt the flywheel back on about 3 times to get it straight. Good thing I tested it before installing the t4 and d300!