Tools and Materials Needed:
- Jack and jack stands
- Transmission jack
- Clutch kit (includes new clutch disc, pressure plate, release bearing, pilot bearing, and alignment tool)
- Flywheel resurfacing tool or machine shop service
- Brake fluid
- Penetrating oil or lubricant
- Socket set
- Wrench set
- Screwdriver
- Pliers
- Safety glasses
- Gloves
Step 1: Prepare the Vehicle
- Park your T100 on a level surface and engage the parking brake.
- Loosen the lug nuts on the front wheels but don't remove them completely.
Step 2: Raise the Vehicle
- Place the jack under the front of the vehicle and raise it until the front wheels are off the ground.
- Secure the vehicle with jack stands.
Step 3: Remove the Transmission
- Disconnect the negative terminal of the battery.
- Remove the front wheels.
- Remove the starter.
- Disconnect the clutch cable or hydraulic line.
- Remove the transmission cross member.
- Support the transmission with a transmission jack.
- Remove the transmission bolts and separate the transmission from the engine.
Step 4: Inspect and Resurface Flywheel
- Inspect the flywheel for wear, cracks, or heat spots.
- If necessary, resurface the flywheel using a flywheel resurfacing tool or take it to a machine shop for professional resurfacing.
Step 5: Replace Pilot Bearing (Optional)
- If your T100 has a pilot bearing, remove the old bearing from the crankshaft using a suitable tool.
- Install the new pilot bearing into the crankshaft.
Step 6: Install Clutch Disc
- Align the clutch disc with the splines on the input shaft of the transmission.
- Carefully slide the clutch disc onto the input shaft. Make sure it is seated properly.
Step 7: Install Pressure Plate
- Position the pressure plate over the clutch disc.
- Install the pressure plate bolts and tighten them evenly in a star pattern to the specified torque.
Step 8: Install Release Bearing
- Depending on your T100 model, you may have a hydraulic or mechanical clutch release system.
- If it's hydraulic, inspect and replace the release bearing if necessary.
- If it's mechanical, lubricate the release bearing and install it onto the clutch fork.
Step 9: Reinstall Transmission
- Carefully align the transmission input shaft with the clutch disc.
- Install the transmission bolts and tighten them evenly in a star pattern to the specified torque.
- Reinstall the transmission cross member and other components you removed earlier.
Step 10: Reconnect Components
- Reconnect the clutch cable or hydraulic line.
- Reinstall the starter.
- Reconnect the negative terminal of the battery.
Step 11: Bleed Clutch System (if necessary)
- If your T100 has a hydraulic clutch system, bleed the system to remove any air.
Step 12: Test Drive and Adjust
- Lower the vehicle and remove the jack stands.
- Test drive the vehicle to ensure the clutch is functioning properly.
- If necessary, adjust the clutch pedal free play according to the vehicle's specifications.
Note:
- This guide is general, and specific procedures may vary depending on your exact T100 model and transmission type. It's recommended to consult a vehicle-specific repair manual or seek professional assistance if you're not confident in performing this repair.
