Hi all! Just picked up a 97 Montero Sport 4x4 with a manual transmission. Needed a clutch and has a stiff shifter in 1st, 2nd, 3rd and 4th.

I pulled the transmission/transfer case and found the clutch was toasted down to the rivets.

1st problem. I forgot to mark the old clutch when I pulled it. It took a couple of days to get the flywheel resurfaced. Now that I'm ready to reassemble I have forgotten which direction the clutch goes. Raised/sprung side goes against the flywheel or the pressure plate? It fits in both ways.

2nd problem. Having a hard time tracking down my shifter issue. There only seems to be a white nylon bearing/bushing that pops down into the transmission. I reattached the shifter while the trans is on the bench and it is almost stiffer now than it was in the car. Goes in 5th and reverse easily.

Thanks for any advise/help, I've been browsing though the search feature but it doesn't seem to be yeilding much help.

 

You should see clear difference between the sides - raised side is the one that was probably resurfaced. It should go out towards the clutch disk and the pressure plate. I doubt that they would resurface the back end of the flywheel, so that should not have any fresh markings on it and look a little duller. That would be the side towards the engine.

 

Yes, the flywheel is obvious which side is out. It's the clutch disc that I'm talking about. The raised side fits inside the flywheel recess where the flywheel bolts are so it can be put on backwards if I'm not careful, which I'm not. Doesn't matter which way I put it in, the pressure plate tightens down the same way so I won't know if I got it wrong until the Trans is back in, which is a pain since it's giagantic.

 

is the clutch plate not marked with CW or arrows or "flywheel side"?
Not having done one on you model, i'm going to guess (50/50, right?) that the springs should be on the box side!

 

The part on the clutch disk that sticks out should go towards the pressure plate. Did you get new pressure plate too? If your clutch disk is as worn out as you describe, it would be prudent to replace the pressure plate.

 

Yes, full clutch kit. New disc, pressure plate, pilot and throw out bearings.

 

Good deal. Let us know how you fair with the repairs. Sorry can't answer your question about the bushing.

 

Truck is back on the road and super strong. Mowing through manual gears in big SUV is a weird experience that I'm really starting to dig.

Now I just need to find a way to make more power.