After getting the new tune, the clutch was slipping at 40-50mph when getting on the throttle. So the plan to replace the clutch next winter turned into replacing it last weekend. Although it was a challenge, it was fairly straightforward. Here are the steps I used to get the clutch replaced. Hopefully it can help the next guy. I ended up going with the clutch and pressure plate from Diesel Freaks. Very happy with how much stronger the upgraded clutch/pressure plate is over stock. This procedure took probably about 8-10 hours total, but much of it was learning what had to come out.
Disconnect battery terminal
Need to remove the starter. We don't want any sparks if the starter wires hit the frame
From the cab - remove Tranny shift arm:
Put Tranny in Neutral before starting - will need neutral to make sure gears align when installing transmission
Remove the big plastic housing that the boot is attached to so you can gain access to the transmission shift lever attachment area.
Cut plastic tie-wrap holding the rubber boot to the actual transmission
Remove 2 bolts on each side to get the plungers and springs for centering the shift arm out
Remove 3 bolts holding silver plate to transmission
Remove transmission shift lever and put to the side
Plug hole in transmission with rag to keep dirt out
Remove Starter
3 bolts - 2 from the bottom, one from the engine compartment
Remove Rear drive shaft
Have to totally remove rear drive shaft
Disconnect front drive shaft from Transfer case
Disconnect 3 wires connected to Transmission/Transfer Case
RPM Sensor
Speed Sensor
Reverse Sensor?
Remove hydraulic clutch plunger
2 bolts
Put jack under skid plate for Oil Pan
Put Transmission Jack under transmission/Transfer case
Remove bolts from bell housing for Transmission
5 small bolts for dust shields must be removed - 3 on bottom, 2 on Passenger's side
Remove 2 larger bell housing bolts from top
Remove longer 2 bell housing bolts from bottom
Pull transmission
Will need to lower as you remove to clear the bell housing from the Roxor body
Tranny will NOT come out without shift lever removed totally - there is not enough room to drop tranny.
Clean throwout bearing and transmission in general
Grease throwout bearing shaft/arm/etc
Remove old pressure plate and clutch
Install new pressure plate and clutch
Comes with new bolts/lock washers - I did not use loctite
Install locating tool before you tighten bolts
Remove locating tool when everything is tight
Install tranny/transfer case with tranny jack
Lining this up is a challenge and requires 2 people
Be careful when installing 4 bell housing bolts
Make sure nothing is binding and that everything is lined up before closing the gap between the bell housing and the engine.
Leave Hydraulic plunger for the end
When everything is back together, I had to open the bleed valve on the hydraulic plunger in order to compress it enough to install. Once installed, I bled the hydraulic plunger by pressing on the clutch and opening the bleed valve for a brief instant
When connecting the 3 wires, Make sure the RPM sensor is connected correctly. It wasn't connected totally when I tried starting the Roxor. The Roxor will NOT fire and will not run if that sensor is not reading correctly. Took a bit to figure that out.
New clutch is MUCH stronger than the stock. Takes a bit more to push in, but feels much more stout than before. Pressing/releasing clutch takes a slight bit more effort, but nothing that would cause issues with most drivers.