1. Preparation is Key:
* Safety First: Disconnect the negative battery terminal. Use jack stands securely to support the car after lifting it. Wear safety glasses and gloves.
* Gather Tools and Parts: You'll need a complete set of metric sockets and wrenches, a clutch alignment tool (absolutely essential), a torque wrench, a transmission jack (highly recommended), a shop manual specific to your Festiva, new clutch disc, pressure plate, throw-out bearing, pilot bearing (if needed), possibly a new clutch cable, and possibly a new flywheel if it's damaged.
* Consult a Repair Manual: A Haynes or Chilton manual for your specific year and model is crucial. It will provide detailed instructions, torque specifications, and diagrams. Following these instructions precisely is essential.
2. The Repair Process (General Steps):
* Drain the Transmission Fluid: This is vital to minimize mess.
* Disconnect the Drive Shaft: Separate the drive shaft from the transmission.
* Remove the Transmission: This is the most challenging part. You'll need to disconnect various linkages, remove the starter, and likely unbolt the transmission mount(s). A transmission jack will make this significantly easier and safer.
* Inspect the Flywheel and Clutch: Carefully inspect the flywheel for cracks, scoring, or excessive wear. Replace it if necessary. Examine the old clutch components to understand the condition and help guide your assessment of new parts.
* Replace the Pilot Bearing (if necessary): This bearing guides the transmission input shaft onto the crankshaft. Often it requires special tools for removal and installation.
* Install the New Clutch: Carefully install the new clutch disc, pressure plate, and throw-out bearing using the alignment tool. The alignment tool ensures the clutch disc is properly centered.
* Reinstall the Transmission: Carefully lower the transmission back into place using the transmission jack. Reconnect all linkages and bolts.
* Reconnect the Drive Shaft: Securely attach the drive shaft.
* Refill the Transmission Fluid: Use the correct type and amount of transmission fluid specified in your repair manual.
* Bleed the Clutch Hydraulic System (if needed): If your Festiva has a hydraulic clutch, bleeding the system is critical to restore proper clutch operation.
* Test the Clutch: Carefully test the clutch engagement and disengagement. Listen for any unusual noises.
3. Important Considerations:
* Torque Specifications: Following the correct torque specifications for all bolts is critical to prevent damage and ensure proper function.
* Alignment Tool: Using the correct clutch alignment tool is absolutely essential to prevent damage to the clutch and transmission.
* Professional Assistance: If you're unsure about any step, seek professional help. Improper repair can lead to significant damage to your vehicle.
Disclaimer: This is a simplified overview. Attempting this repair without a detailed repair manual specific to your 1991 Ford Festiva is strongly discouraged. Improper repair can result in serious damage to your vehicle and potentially injury to yourself. Always prioritize safety and consult a professional mechanic if needed.
