Need tips on installing new clutch.

David (5spd GT) and Joe did a good write-up on the infamous clutch install. Lots of wisdom in THIS post.

Tim

brown tranny fluid means it needs to be replaced

when i was checking my clutch, we pulled the tranny and bellhousing separately, so it wasn't too hard to get to the top bolts

top starter bolt IIRC either with an extension, or i think there's a hole in the suspension that lets you get to that bolt.
yes, support the back of the engine after you pull x-member, otherwise your fan will hit your fan shroud or you could rip vacuum lines, or other things. its easier to get to the top bellhousing bolts with the engine dropped slightly in the back, makes more room for work, but just be careful about how much you let it drop

To get those top bolts on the bell housing let the engine lean back a little then you can get right in there..I got the top starter bolt from the front of the car with a long extension and one of those craftsman tools for taking a rounded bolt off. That thing always leaks when you take the driveshaft out.

Since your starter bolts are rounded off (or atleast one of them) I have a part number for new ones in the link given my Tim above in my write-up.

Yep, change that tranny fluid

I've never installed a clutch on an engine that was in the car, so I need some tips to make it easier because I've never taken my cars to a shop to have them worked on and don't plan on it either.

-The actual clutch replacing part is pretty easy - removing a rusted on H pipe, and figuring out how to get the starter off etc etc is the hard part.

How do I get to the upper bell housing bolts?

-After the tranny is out, use 2-3 6" extensions (or 1 12" extension) and a universal adapter and that will allow you to get those bolts out - may need a 3/8" breaker bar and a pipe extension to allow more leverage - you may bust your ratchet otherwise.

How do I get the top starter bolt out?

- go over the top of the passenger side motor mount with three 6 " extensions - if you remove the passenger wheel, you can see the bolt - that's actually how I take it out is through the wheel well.

Do I need to support the rear of the engine after the transmission has been removed?

- once the tranny is out, the engine is balancing on 2 mounts - use a scissor jack (or whatever) with a piece of a 2x4 to support the engine

So, now, I still have an old clutch in my car and now have a leak around the seal where the yolk goes into the tranny. :damnit:

And what does it mean when the tranny fluid that comes out is brown?

- Brown fluid = bad fluid - should be a clearish red color - make sure you drain the tranny unless you want a bath in the stuff!

Good luck - take you're time - all a clutch change is, is unbolting and bolting back up - sure you need to make sure your torque values are right, and everthing is lined up right, but you are not fussing with backlash etc etc and stuff like that.

Before you get started, buy a Chilton or Haynes shop manual. You will need it for the bolt torques and patterns.

1.) Jack up the car front and rear, use jack stands to be safe.
2.) Put a 2x4 wood block under the engine oil pan to support the engine. Jack it up slightly. This prevents damage to the motor mounts when the transmission mount is removed. The oil pan is plenty strong for this purpose.
3.) Label all the wiring for the transmission before disconnecting it. Disconnect the O2 sensor cables at their connectors. Disconnect the speedo cable by pulling it straight out of the VSS sensor, or by removing the bolt that holds the VSS sensor in place. If you remove the VSS sensor, zip bag & tag it along with the bolt that secures in place.
4.) Remove the drive shaft, the rear bolts are 12 MM. You will need a high quality 12 point wrench for this: do not skimp or you risk rounding off the bolt heads. A helper to step on the brake to keep the drive shaft from turning will be helpful. Use your foot to apply pressure to the wrench to loosen the bolts. Note the yellow markings in the drive shaft and write down their alignment.
5.) Put a catch pan under the rear of the transmission to catch the fluid when you slide the yoke out of the transmission. I recommend that you drain the transmission at this time. There is a pair of pipe plug filler ports on the side of the transmission. Use the lower plug to drain the fluid.
6.) Inside the car, remove the shifter boot and then remove the shifter handle
7.) Remove the H pipe & rear trans cross member. The chassis to cross member bolts are metric, you need a 15 MM & 17 MM socket or wrench. Note the direction and size of the humps on the cross member and write it down. Inspect the rear transmission mount and replace if damaged.
8.) Remove the transmission. You will need a long extension & a universal joint with a ¾” socket. A transmission jack or a helper is almost a must have unless you can bench press 75-100 pounds with ease.
8.) Remove the clutch cable cover and pry the throwout bearing arm forward enough to slide the cable off.
9.) Remove the bell housing using the long extension & a universal joint socket. Note how the throwout bearing rides it the throwout bearing arm, and which end faces the clutch pressure plate. Write it down or make a drawing if necessary.
10.) Remove the bolts securing the pressure plate to flywheel. Be sure to label & zip bag them separately from the rest of the parts. Work in a star pattern to reduce stress on the pressure plate mounting tabs.
11.) Remove the flywheel mount bolts, as you will need to either replace or re-surface the flywheel. Be sure to label & zip bag them separately from the rest of the parts.
12.) Inspect the transmission input shaft where the throwout bearing rides. Replace it if worn or damaged.
13.) Inspect the throwout bearing, throwout bearing arm and ball pivot stud for wear or damage.
14.) Inspect the rear oil seal for leakage and replace if required.
15.) Remove & replace the pilot bearing. A puller borrowed or rented is helpful here. A wood block will be used to drive it home.
16.) Install the flywheel, noting that the bolts are an odd pattern, and it only lines up one way so that all the bolts go in easily. Torque to specs according to the shop manual.
17.) Install the clutch disk with the hub springs facing the rear of the car. Use a pilot tool available for $3-$4 from the auto parts store to line it up.
18. Install the pressure plate, be sure to use the pilot tool prior to tightening the pressure plate bolts. Torque to specs according to the shop manual. Remove the pilot tool when you are finished torquing the bolts.
19.) Install the throwout bearing on the throwout bearing arm, noting the direction of the bearing and it mounting in the arm.
20.) Install the bell housing. Torque to specs according to the shop manual.
21. Install the transmission, have the transmission jack or helper at hand to lift it into place. Watch out that the stub of the shifter does not tear the shifter boot. Some 7/16 bolts with the heads cut off can be used to help support the transmission as you slide it home. It may be necessary to press the clutch pedal to get the transmission to slide the last ½” or so. Remove the guide studs if you used them & torque to specs according to the shop manual.
22.) Reinstall the clutch cable by prying on the throwout bearing arm. Replacement of the stock cable or quadrant is recommended if you haven’t already done so. With adjustable cables, both nuts go on the back side of the throwout bearing arm.
23.) Reinstall the rear crossmember & transmission mount. Torque to specs according to the shop manual.
24.) Reinstall the wiring and speedo cable or VSS sensor if you removed it.
25.) Reinstall the drive shaft, slide the yoke in place. Align the rear yellow markings and install the bolts. A helper to step on the brake to keep the drive shaft from turning will be helpful. Use your foot to apply pressure to the wrench to tighten the bolts.
26.) Remove the jack from under the engine oil pan.
27.) Refill the transmission with the proper fluid. T5’s use Dextron ATF, Tremec 3550’s use GM Synchromesh. There is a pair of pipe plug filler ports on the side of the transmission. Use the top plug as the filler port.
28.) Adjust the clutch cable according the manufacturer’s instructions if you have an adjustable cable & quadrant. Set the emergency brake and use the drag it provides in order to determine where the clutch starts to engage. You should have 1 -1 ½” free play from the top. The cable will not have any slack and will have some preload on it when properly adjusted.
29.) Re-install the H pipe and remaining items.
30.) When you have visually checked all the bolts, fittings and other parts are present and not interfering with each other, then take the car down off the jack stands.
31.) Be prepared to put the car back up on the jack stands to adjust the clutch and tighten up any loose items found after the test drive..

jrichker comes thru again

one thing though that may or may not be stated in haynes/chilton manual, put a dab of grease on the pivot ball of the clutch fork... it will come in handy