- Safety Glasses
- Oil Filter Wrench
- Pliers
- Needle Nose Pliers
- Pry Bar
- Ratchet
- Extensions (different lengths)
- Combination wrenches
- 1 ½ inch or 2 inch Socket with extension
- Clutch Cable Wrench
Instructions:
1. Before starting, make sure the engine is cool and that the transmission is in neutral.
2. Disconnect the negative battery cable to prevent electrical accidents.
3. Remove the air filter and filter housing.
4. Use a pry bar to remove the cotter pin from the clutch fork arm and remove the clutch cable from the clutch fork arm.
5. Loosen and remove the four nuts holding the clutch master cylinder to the firewall. Gently push the master cylinder out of the way, taking care not to damage the brake lines.
6. Loosen and remove the starter bolts.
7. Raise the vehicle using a floor jack and place jack stands under the front and rear axles to support it securely.
8. Remove the driveshaft by unbolting the four bolts connecting it to the transmission tailshaft housing and the two bolts connecting it to the rear differential.
9. Lower the vehicle and move it to the front and rear, shaking it gently side to side if necessary to help the transmission fully disengage from the engine block.
10. Remove the lower bell housing inspection plug.
11. Position a transmission jack under the transmission and raise the transmission and engine slightly to relieve the weight on the transmission mount bolts.
12. Remove the four nuts holding the transmission mount to the cross member.
13. Remove the cross member by removing the four bolts securing it to the chassis.
14. Remove the upper bell housing inspection plug. Insert a clutch alignment tool.
15. Remove the clutch release fork pivot ball nut located on the left side of the bell housing and remove the fork bracket and fork arm assembly.
16. Remove the bellhousing bolts.
17. Gently tap the bell housing with the pry bar to loosen it and carefully pry the bell housing away from the engine block, being careful not to drop the clutch and pressure plate onto the ground.
18. Inspect the clutch friction disc and pressure plate for damage or wear and determine whether replacement is necessary.
19. Use a wire wheel or sandpaper to clean the flywheel mating surface.
20. Apply a small amount of high-temperature grease to the splines of the input shaft.
21. Carefully place the new clutch and pressure plate assembly onto the flywheel, ensuring that the clutch disc is properly aligned with the splines of the input shaft.
22. Install the clutch release bearing and fork assembly.
23. Install the pilot bearing.
24. Reinstall the bell housing, using new gaskets if necessary. Tighten the bellhousing bolts to the specified torque.
25. Install the rear crossmember.
26. Raise the transmission slightly into position and install the crossmember and mount, if not bolted yet.
27. Install the new throw-out bearing.
28. Reinstall the starter.
29. Reinstall the driveshaft. Use new transmission mount nuts.
30. Reinstall the clutch master cylinder.
31. Reinstall the clutch cable and cotter pin.
32. Reinstall the air filter assembly.
33. Reconnect the negative battery cable.
34. Fill the transmission with the required amount of the correct type of transmission fluid.
35. Test the clutch operation by starting the engine and shifting gears through the full range of positions. Ensure the clutch engages smoothly without slipping or grabbing.
