I am going to put a clutch kit into a 1994 2 door tracker with a 5 speed. I see there are two different ones and wonder which one to get or which one I have to use ? There is a 7 7/8" diameter and a 8 1/2" diameter kit .
I assume the 8 1/2" would have more surface area and hold up longer  . But I don't know for sure.
Thanks,
Raz

you better take your old one out, they have different splines

When I was looking on O'reillys ,autozone and Napa . I thought they all had 20 splines
Raz

Get the 8.5" one.  It will fit fine.  There are no spline differences between them.
The 7 7/8" is a stock sized replacement for the 8V engine.
The 8.5" is a stock sized replacement for the 16V engine.
The 8V and 16V use the same flywheel, so you can use either clutch behind either engine.

Do I have to get a new flex plate assy if I go with the 8.5 ?
Raz

Do I have to get a new flex plate assy if I go with the 8.5 ?
Raz

Do you mean pressure plate?  If so, then a clutch kit will come with a pressure plate, the fiber plate, probably a pilot bearing, and maybe a throw out bearing.

Yes, I mean pressure plate . Do you recommend having the flywheel resurfaced  ? Do they usually do this on a lathe or surface grinder ?
Thanks,
Raz
 

Yes, I would have the flywheel resurfaced.
Depending on the shop, they can do it either way.  Surface grinding is better, IMO.

I am a Journeyman tool and die maker and have access to a full machine shop so I will be doing it myself. I do have a small machine shop at home  with two milling machines,large drill press,lathe and surface grinder but my grinder is down right now . So, I will just take the flywheel to my work and use their grinder , that is if they still will let me in even though I am laid off.
Thanks,
Raz

I bought the 8.5 one for my tracker, the splines were different wouldnt fit.  but try anyways, maybe mine was a one off

So, I should make sure it is a 20 spline ?
Thanks,
Raz

I bought the 8.5 one for my tracker, the splines were different wouldnt fit.  but try anyways, maybe mine was a one off

They must have had a fiber plate from some other vehicle in the box.  I know for a fact that they are interchangable, because I am running a 7 7/8" clutch in my 95 4 door with the 16V (which had the larger 8.5" clutch in it when I pulled it).

Is there a benefit if the 7 7/8 or is it just what you had laying around ?
Thanks,
Raz

Is there a benefit if the 7 7/8 or is it just what you had laying around ?
Thanks,
Raz

No. No benefit at all to running the smaller clutch.  It was on one of my parts vehicles, so I just used it instead of buying a new clutch.  I just use my 95 as a DD, so it doesn't really make any difference if I run a smaller clutch on it, since I am not slipping and popping it like I would be off-road.