Minimum special tools for doing the TB without doing the water pump are the exhaust and intake cam pins (Miller VM.1053 and VM.1052 - some have fabricated a substitute from bolts but under no circumstances try to get by with allen wrenches as a substitute - I've posted pin dimensions at
viewtopic.php?f=5&t=67007&p=737953&hilit=dimension#p737953); a 6mm allen wrench for a flywheel pin (see the 2005 FSM pg 9-243 for a how to use it - it's a good idea to "tap" around the hole in the flywheel to make sure you are putting the allen wrench in a smalll flywheel hole not one of the larger cutouts.); and a TB tensioner wrench (there is a Miller tool but you can make your own with a flat piece of metal and a couple of proper size bolts/nuts or use the allen key trick in the GDE timing belt change writeup at
http://www.greendieselengineering.com/f ... st/72.page).
Take it slow, make lots of witness marks and you will be fine. Tedious but not hard. Physically hard part is getting fan and shroud off (see my comments at
viewtopic.php?f=5&t=69251&p=740783&hilit=shroud#p740783) and consider a shroud mod to make future access easier (see
viewtopic.php?f=98&t=64278&p=709322#p709322)
Good how to writeups are at
viewtopic.php?f=5&t=60858 (pulling all that front end stuff is not required but does make access easier) and
http://www.beesvillebeefarm.com/jeep.html (ignore water pump steps)