Trans / Clutch replacement (long)
OK get ready, and get a shop manual of some sort to reference.
READ this several times AND refer to manual before attempting this procedure!!!!!!!
Make sure that you have all the parts and tools: New clutch assy., throw out bearing, new slave cylinder and pilot bearing. Tool to disconnect hydraulic connector and clutch alignment tool.
1.You're gonna need a lift or some tall ramps or heavy jack stands. (you have to get the car high enough off the ground to to fit the trannies) It's a royal PITA to do it on the floor but it can be done(I know!)
2. Transmission jack or adapter for floor jack.
3. Drain the trans.
4. Disconnect the battery.
5. Remove the console, shifter boot and unbolt shift handle.
6. Once you get the car up, use a Good 12 mm box wrench and undo the rear u-joint u-bolts. Then pull the shaft forward free of the pinion, then push it up and back stuffing it over the diff. (this way you don't have to pull the gas tank).
7. Pull the starter.
8.Remove the front half of the exhaust.
9. Disconnect wiring harness.
10. Disconnect clutch hydraulic line and bag it to keep out dirt.
11. Position trans jack. MAKE SURE it's supporting the trans.
12. Start removing bolts from bellhousing (REMEMBER which ones went where).(It's probobaly best to put something under the oil pan to support the engine when you pull the trans)
13. Remove the trans crossmember.
14. (It's best to have someone else there for this step) Make sure all the transbolts are removed (top ones need a long extension. Then slowly pull the trans back to to disconnect from engine. you may need to let the engine drop a little to let the trans come back. Be careful cuz it's a little heavy. Lower trans and remove from jack.
15. Remove clutch assy from flywheel.
16. Use a slide hammer with inside jaws or large wooden dowel and some thick grease and a hammer to pop out the input bearing (dowel has to bearly fit inside the brg)beware of the grease when it pops.
17. Clean pilot hole and flywheel and insert new brg.(should be prelubed)
18. clean flywheel again this time use brake cleaner to remove ALL grease and oil.
19. Bolt on (do not torque yet) pressure plate and new disk. (SAKS makes a complete set thats not to expensive, comes with pressure plate disk, throw out, pilot brg and alignment tool. Have to get Slave cyl seperate)
20. insert alignment tool, when all is sat, torque.
21. Inspect new/used trans, remove slave if attached and clean inside bell housing. Might want to remove rear seal and install new one (safe).
22. Install new slave cyl.
23. When all is ready, mount trans on jack and lift into position.(make sure trans is in gear so you can turn the output shaft to position the input shaft when mating trans to engine) Match angle of trans to engine to make for smoothest insertion.
24. Ease trans input shaft into clutch assy and pilot brg.
25. Align bellhousing locating pins and push.
26. Install a bolts in belhousing.
27. Install trans crossmember.
28. Connect hyd line, add brake fluid to clutch resivore and bleed.( careful not to get fluid on clutch assy!!!!)
29. Connect wiring harness, exhaust, starter and driveshaft.
AS I STATED AT THE BEGINNING, READ SEVERAL TIMES AND READ THE BOOK BEFORE STARTING, JUST TO BE FAMILIAR WITH THINGS!! I DID THIS FROM MEMORY, ANYTHING I MAY HAVE LEFT OUT OR NOT ELABORATED ON IS COVERED IN THE BOOK.
Good luck. Mike