overview of a 87-93 clutch install
Raise vehicle as high as possible, both front and rear if possible
Drain transmission (lower bolt on passenger side, 3/8 drive
wrench fits the square hole)
Shoot some penetrating oil on the cat-back bolts and the H-pipe
to header bolts and the crossmember/h-pipe hangers
Remove driveshaft by using a 12-point 12mm wrench on the 4
bolts and LOTS of leverage
Remove O2 sensors
Remove H-pipe (pre-lube the hangers to make things easier)
Remove the shifter by removing teh knob, pulling up and removing
the trim plate, and removing the 4 bolts holding the shifter
on (8mm I think)...pop it with a screwdriver from under the
car if necessary.
Disconnect clutch cable from fork by removing inspection cover
and pressing fork forward to release tension on the cable, slide
cable end over to hole and out
Undo the speedo cable and electrical connections from trans
Support transmission and remove crossmember
Remove the bolts holding trans to bellhousing
Shift trans rearward and then down and out of the car
Remove the bolts holding the bellhousing to the engine
Remove the dust plate
Now you're staring at the pressure plate, shift fork and t/o
Unbolt the pressure plate and be careful, the assembly is heavy...do
remove pressure plate and clutch disc.
If changing flywheel, unbolt it and remove it.
If changing pilot bearing (good idea while you're here) remove
flywheel and use a puller or the hydraulic method to remove
pilot bearing, replace with new one and tap to seat.
Clean all surfaces with brake cleaner, do not under any circumstances
leave any trace of oil or grease anywhere on the contact surfaces
of the flywheel, cllutch, or pressure plate
Install flywheel if removed, using RTV on the bolts.
Using a clutch alignment tool, install clutch disc and pressure
plate. Tighten pressure plate bolts evenly and just a little
at a time, taking several passes around to fully tighten. You
don't want it getting tightened down crooked.
When PP is tightened you can remove alignment tool
Reinstall clutch fork and a new throwout bearing. Lube the
face of the bearing where it contacts the clutch fork
Edit: Remember to reinstall that dust plate/shim
Reinstall the bellhousing. Be sure to lube the ball stud where
the clutch fork pivots
Lube the snout of the trans where the T/O bearing rides on
it and prepare to reinstall the trans. Put it on a floorjack
and have a helper get it in place, unless you're strong enough
to bench-press 75 lbs of ornery machinery and finesse it into
It'll go almost all the way in and probably not seat. Reconnect
the clutch cable and have a helper step on the clutch while
you seat the trans the last little bit
Bolt the trans down and basically reverse the removal process
Fill the trans with 2.5 q of Mercon/Dexron ATF through the
shifter opening before installing shifter. Use a thin bead of
RTV aruond the shifter opening before installing.
Use Loctite Blue and plenty of torque on the driveshaft bolts
Use anti-seize on everything else exhaust or tranny related
to make it easier next time.