I. Preparation:
1. Safety First: Disconnect the negative battery cable. Support the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
2. Gather Tools & Parts: You'll need a complete clutch kit (pressure plate, clutch disc, throw-out bearing), a transmission jack (essential!), various sockets and wrenches (metric), a torque wrench, a clutch alignment tool, pry bars, possibly a flywheel resurfacer, and plenty of rags. Consult your repair manual for the exact tools and parts needed.
3. Drain Transmission Fluid: This is crucial to prevent a messy spill. Have a drain pan ready.
II. Removal:
1. Disconnect Components: Disconnect the driveshaft (at the rear differential and transmission), the slave cylinder, and any other components connected to the transmission.
2. Remove the Transmission: This is the most challenging part. Use the transmission jack to support the transmission as you disconnect the bellhousing bolts and carefully lower the transmission.
3. Inspect the Flywheel: Inspect the flywheel for cracks, scoring, or excessive wear. It might need to be resurfaced or replaced.
4. Remove the Clutch: Once the transmission is out, you can remove the old clutch components (pressure plate, clutch disc, and throw-out bearing).
III. Installation:
1. Install the New Throw-out Bearing: Install the new throw-out bearing into the transmission housing.
2. Install the New Clutch Disc: Use the clutch alignment tool to correctly center the new clutch disc on the input shaft.
3. Install the New Pressure Plate: Carefully install the new pressure plate, ensuring it's correctly aligned. Tighten the pressure plate bolts to the specifications in your repair manual.
4. Install the Transmission: Carefully guide the transmission back into place, using the transmission jack for support. Reconnect the bellhousing bolts and tighten them to the correct torque specifications.
5. Reconnect Components: Reconnect the slave cylinder, driveshaft, and other components you disconnected earlier.
6. Refill Transmission Fluid: Fill the transmission with the correct type and amount of fluid (check your manual).
IV. Testing:
1. Start the Engine: Once everything is reconnected, start the engine and check for leaks.
2. Test Drive: Carefully test drive the vehicle, checking for smooth shifting, and any unusual noises.
Important Considerations:
* Flywheel Resurfacing: A scored flywheel can cause premature clutch wear. Consider having it resurfaced professionally if necessary.
* Pilot Bearing: The pilot bearing might need replacement as well.
* Slave Cylinder: If the slave cylinder is leaking or worn, replace it while you're doing the clutch.
* Torque Specifications: Follow the torque specifications in your repair manual precisely. Using incorrect torque can damage components.
* Professional Help: If you're not confident in your abilities, hire a professional mechanic. A improperly installed clutch can cause significant damage to your vehicle.
This is a simplified guide. Refer to a detailed repair manual specific to your 1998 Chevy S-10 for precise instructions, torque specifications, and diagrams. Improper installation can lead to serious damage, so proceed with caution and consult a professional if you're unsure about any step.
