I'm a bit nervous but yet excited...replacing clutch

[Thorbolter]

I took off work today and tomorrow to replace the clutch in my 92 explorer sport 4x4. I will have to remove the transmission and then the transfer case before I can even get to the clutch. I am a bit nervous because this is my first major project on the explorer and I have never removed a transmission before. Actually this will be the most work I will have done on any car. I replaced the front brakes and front brake rotors on the ex but I have a feeling this will be a bit harder. I will be headed out there soon to get started, but you can be sure that I will be back to ask questions every once in a while.

Oh, bought a new clutch from autozone for 122, slave cylinder for 85, and a pilot bearing for 15. Going to check the plugs when I pull the tranny, if they are the rubber ones then I will replace them. Anything else I should check? Will also be removing the old exhaust and putting on flowmaster catback II exhaust.

 

[MyExpWork]

Make sure to inspect the flywheel for any scoring, burning or other foreign material...In fact you may just as well take the flywheel off and have it machined by a shop..that would be your best bet.

Why did you buy a new slave cylinder? Is it required to replace that when you replace the clutch on the Explorer? My old 5-speeds never had to do that, but I have never done a clutch job on a Ford so it may be different.

Good luck and prepare to spend all day on the clutch.

Brian

 

[410Fortune]

You can drop the tranny and t case as a single unit.

Do yourself a favor and remove the Y pipe from the exhaust first, saves time

Have a shop (carquest) turn your flywheel and replace the pilot bearing.

Good luck! I had my tranny down 4 times last year and once this year, no more clutch's for me!!!

 

[Thorbolter]

I read on here to go ahead and replace the slave cylinder while I am replacing the clutch.

Have a shop replace the pilot bearing? It looks simple enough. I got the bearing puller from autozone. *shrugs* Something you know that I don't?

Yes, planned to get the flywheel resurfaced no matter what. Want that clutch to break in smooth.

I can drop the tranny and the t-case at the same time? Hmm, Haynes doesn't mention this, how do I go about doing it?

Thanks.

 

[410Fortune]

The transmission and transfer case are attached as one unit. They are both supported ny the trannym mount.

You can leave the front driveshaft attached to the transfer case and you can leave teh transfer case bolted to the tranny, not as messy because you wont lose much ATF unless you let the tranny tip over.

It makes it a little harder to manuever, but it saves time.
You can drop the transfer case from the tranny, but I never did, if you do you will want to replace the gasket that goes between them.

While they have the flywheel out they can drop in a pilot bearing, total cost is like $40, so not a big deal, I just let them deal with the pilot bearing.

Every single time you have the tranny down for a clutch you should replace the slave cylinder, it's worth it.

good luck! Oh and dont let the little crush collar fitting on the hydraulic line slow you down. Use two small flat head screwdrivers. Push the white plastic collar ALL the way into the sleeve, and then the line will pull off with no problem. It is kind of like a chinese finger puzzle, you know where you have to push the collar in while making sure not to pull on the hose, until it is all the way in. You will see what I mean when you get there.....

 

[Thorbolter]

Chugging along here. Got the ex up on two front jack stands. Should I put the rear up on jack stands too? Doesn't look like I need to but if it is easier then I will do it. The shift lever was a bit tight to get out but it came out. I am draining the transmission fluid right now. The drain plug looks kind of nasty. It has metal shavings and some gray gook on it. Should I be concerned now about the transmission? It has 148k on it and I have had it since 92 when i bought it new. The ex had it for a year but she took good care of it. Well, giving the transmission a few more minutes to drain then on to the next step. Oh yeah, when I keep the transfer case attached to transmission, in the Haynes manual, what steps should I skip around? Damn its hot outside.

 

[410Fortune]

If you jack up the whole truck it makes it easier to get your head in there and do the clutch and flywheel work. It is also easier to stab the tranny with the truck level then it is to stab a tranny at an angle.

It's self explanitory, If you remove the transfer case from the 5 speed you will have to deal with the gasket that goes between them. If you leave them together it will be slightly heavier and a little more awkward when it's time to stab, I never saw the need and I did my clutch several times by myself with simple hand tools and a floor jack with wooden blocks.

I rented a tranny jack once, and ended up not using it, it was more trouble then it was worth. the 5 speeds and t cases on these trucks are small and light, so (especailly if you have a helper when it comes stab time) it's not all that hard to get it up there and stabbed.

Oh and FYI clean the crap out of the bellhousing, and back of the engine before re-installing.

Oh and the starter is a PITA to get on and off because of clearance issues. I have a 17mm wrench (not all starters are 17mm I have found, different years have diff bolts???) that I cut in half, it fits in there easier to tighten/loosen the upper starter bolt.

The Hanyes manual is a good guide, but it doesnt include all the steps (like removing the Y pipe) and tricks of the trade.

Man all we need now is an internet cam and a lap top, then you could do an online clutch job and call it the tranny cam.....

 

[Thorbolter]

OK. Thanks a bunch. Should be finished draining by now. Break time is over. hehe

I am keeping good notes and I will actually use my digital camera and take pics as I do each step. Make a clutch replacement guide and a removing tranny replacement guide.

Oh and I went and bought a tranny jack for $50 at that frieght line tools place. its cheap and can hold 450 lbs but it looks like it will be better than a floor jack.

Thanks again.....you can bet I will be back on my next break and ask more questions.