Hey islandvitara,
Its easy enough if you have the right tools and someone to help you drop the gearbox out. Hardest thing is dropping the box and putting it back in, just very awkward. I normally do it by myself with some rope and a trolly jack + lotz of swaring. If you do plan on doing it youself I recomend someone to lend a hand with the whole thing.
Tools required--> Good set of 3/8 sockets with a long extension, screw drivers, set of spanners 10 to 17mm + a 10mm ratchet spanner (very handy but not nesesary to remove inspection plate) piece of wooden broom handle, touque wrench, trolly jack & rope.
You may have to support your zook on jack stands if its not high enough to lay under with a bit of room to move.
Step 1.
Remove Gear Shifters.
Take off all plastic trim around shifters & remove boot covers. Loosen 12mm locating bolts on either side of the shifter housing. Push down & turn anti-clockwise the outer lock ring. Remove gear shifter and wrap in a rag. Poke a rag in the hole where the shifter goes. ( You dont want anything falling in there. )
Do as above for transfer shifter.
Step 2.
Remove Drive Shafts.
Drain oil from transfer case. Using 2 x 14mm spanners remove bolts on the front and rear drive shafts and remove.
Step 3.
Dropping the Box.
Dissconnect the Battery! Unplug wiring loom to gearbox. Then remove the starter motor and place to one side. Remove Clutch cable. Remove bolts on lower gearbox/engine mounts (both sides) Remove mounts. Remove clutch inspection cover. Remove 2 x 17mm nuts either side of bell housing. Remove 2 x 17mm bolts top of bell housing. Tie rope around bell housing and up through gear shifter holes. Place trolly jack under the transfer case. Remove gearbox crossmember totally. Using 2 x large flat blade screwdrivers leaver the bell housing away from the motor.
Now this is where you'll need some extra hands. One person under the vehicle steady the box on the jack while the other unties the rope and then you both lower the gearbox to the ground.
Step 4
Clutch Repacement.
Remove all the 12mm bolts holding the pressure plate to the flywheel. Remove clutch plate taking note of the orientation. When replacing the clutch plate with the new one be sure to centre it. This is done but only doing up the 12mm bolts around the pressure plate tight enough so as you can still move the clutch plate using your piece of wooden broom handle. Once you are certain its centred tighten the 12mm bolts to the correct torque specs.
The rest is just the reverse of the removal process. Just dont forget to replace the throwout bearing & make sure you pack it with hi temp grease.
Also you will need to adjust your clutch cable to suit & Dont forget the spacer plate between the bellhousing and the engine. ( Done this myself the first time and wondered why the box wouldnt press hard against the engine. )
Im sure if ive missed anything someone will correct me..
