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Replacing a clutch on any vehicle requires quite a bit of knowledge as well as tools. On the other hand, even if you've never replaced a clutch, the Suzuki Samurai is the perfect vehicle for a beginner to work on. The Samurai is not complicated, it's components are relatively light and are easily accessible. Used and new parts are readily available and the little machines are virtually unstoppable out in the boonies!
In general, the transmission must be removed from the engine. This reveals the clutch and pressure plate. Separating the transmission from the engine block can be accomplished in a couple different ways... some prefer to do the work while under the truck while some prefer to pull the engine/transmission out of the truck and work on the clutch on the bench. Either way works well and is a dirty job :-) To make a full description here would be very lengthy and there would be no photos or drawings to illustrate what is needed.
However... and this is a very big however... a complete factory Suzuki Samurai shop manual is available for not much (how does FREE grab you?) at http:/wwwzperiodzsuzukiinfozperiodzcom This site has a tremendous catalog of Suzuki related information! I recommend every Suzuki owner visit this site and download every manual you can think of that might assist you in the future.
I would also recommend you take a peek at Jim Cambron's Suzuki site at http:/wwwzperiodzacksfaqzperiodzcom An excellent resource for all things Suzuki! Especially helpful is the vacuum hose diagram on Jim's site!
And finally, dance on over to the Zukikrawler's forum and introduce yourself. The guys and gals that live there are Suzuki oriented and super friendly and super helpful. Go to http:/wwwzperiodzzukikrawlerszperiodzcom ... and be prepared for a friendly welcome! Tell them Zukinoobi sent you! :-)
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