Replacement clutch and transmission repair sleeve

[anarchy1024]

Hi all,

I'm thinking it might be time to replace the clutch in my 2003 NA... it doesn't feel like it's slipping after I get moving, but actually getting the Baja moving from a standstill is quite difficult, especially when going uphill. Plus, the current clutch should be quite old, now, and hasn't had a particularly easy life. I was thinking about getting:
- EXEDY 15801 Racing Clutch Kit http://www.amazon.com/dp/B001B5IGIG/
- ACT 600705 XACT Streetlite Flywheel http://www.amazon.com/dp/B00B4CV5ES

I've also been reading that I'll likely need a quill/bearing retainer/extension housing repair kit, which is basically a sleeve and oversized bearing.

sleeve.png (188.29 KiB) Viewed 2976 times

Some kits seem to come with it (http://www.rockauto.com/en/moreinfo.php ... 32&jsn=356), and others don't. Since it appears the Exedy clutch above doesn't come with it, I need to buy one separately... where can I get that from? I found this: http://www.pdmusa.com/OrderStorm-ecomme ... 983B26F09D but the MSRP is $160! The AMS clutch kit from Rockauto includes the bearing and sleeve, and it's $177 for the whole kit. There are some parts listed as Extension Housing Repair Sleeves, but they don't include the bearing, and the pictures/descriptions don't look like the same part... This must be a relatively common part, so I'd think it'll be available somewhere for a reasonable price.

I was also thinking about doing it myself (with a friend's help), and checked out several videos/forum posts on doing it... seems doable, but neither of us have done a clutch job before (did the timing belt with no problems, though). Was thinking about disconnecting the drive shaft and moving the transmission back instead of removing the engine.

Anything else I need or should do at the same time? Pilot bearing? Some said to replace the slave cylinder at the same time?

Thanks!

[anarchy1024]

Also, where can we find the transmission code, besides on the engine bay plate? The transmission in mine was replaced with a compatible, but not exactly identical, unit and I can't find the code for it. The only text I can see on the sides/bottom are "FM-7" and "JAPAN".

Anyone found a extension repair sleeve for less than $150? Seems a bit much considering some clutch kits incldue one for $170...
http://www.42autosports.com/Transmissio ... p_630.html
http://www.flatironstuning.com/p-2601-t ... e-kit.aspx

[anarchy1024]

Any idea what the differences are in the clutch replacement process between a 2003 Baja 5MT and a 1999 2.5RS?

This is definitely one of the most detailed step-by-step DIY guides for replacing the clutch/flywheel I've seen, and it looks like a lot of it will apply to the Baja:
http://www.rs25.com/forums/f105/t128163 ... orial.html