- 1). Disconnect the battery ground cable and set it aside. Raise the pickup with a floor jack and support it on jack stands. Disconnect the exhaust pipe from the manifold and its bracket with the appropriate socket.
- 2). Unplug any wiring harness connectors on the transmission case by pushing the tabs in and pulling the plugs out. Unscrew the speedometer cable at the transmission with the appropriate wrench. Unbolt the drive shaft at the rear then pull it towards the back of the pickup and pull it out of the transmission. Stuff a rag in the drive shaft housing on the transmission so that all the fluid doesn’t drip out.
- 3). Push the transmission up to the engine. Lift it with the floor jack. Line the bell housing up with the engine. Insert all the bolts and tighten them hand-tight. If your engine identification (found on the engine sticker under the hood) is a Z24I or a KA24E, tighten the four long bolts to 30 foot-pounds of torque and the two short bolts to 16 foot-pounds of torque. If the engine identification is a VG30I or a VG30E, tighten the five long bolts to 33 foot-pounds of torque and the four short bolts to 25 foot-pounds of torque.
- 4). Reinstall the starter motor and tighten the bolts firmly. Reattach the starter motor wires with the appropriate wrench. Reinstall the cross-member assembly and tighten all the retaining nuts.
- 5). Reinstall the shifter, rubber boot, slave cylinder and drive shaft with the appropriate sockets. Screw in the speedometer cable with the appropriate wrench. Reconnect the wiring harness plugs on the transmission. Reconnect the exhaust pipe to the manifold and bracket with the appropriate sockets. Reconnect the negative battery cable. Fill the master cylinder with fluid and bleed the clutch if necessary.
- 6). Remove the clutch slave cylinder with the appropriate socket. Put the shifter in neutral, lift up the rubber shifter boot, pry the circlip off the shifter and lift the shifter out of the cavity from inside the vehicle.
- 7). Place a wooden block on the jack. Push the floor jack under the engine and jack it up enough to touch the bottom of the oil pan and support the engine. Slide the second floor jack under the transmission. Remove the cross-member by loosening the rear engine mount securing nuts then pulling the cross-member out.
- 8). Remove the wires from the starter with the appropriate wrench. Remove the starter with the appropriate socket. Unscrew the bell housing bolts, lower the transmission and pull it away from the engine.
- 9). Mark the clutch assembly and the flywheel at the same place with paint or a marker so that the clutch assembly can be put in the same position. Slide the clutch alignment tool (this comes with the new clutch) into the hub to support the weight of the clutch.
- 10
Break the clutch cover bolts loose but do not loosen them completely. Starting at the first loosened bolt, loosen each bolt one turn until all the bolts are loose. Remove the bolts. Do not remove the bolts one at a time as the spring is under tension--removing the bolts one at a time, without loosening them evenly, could cause bodily damage. - 11
Check the flywheel for defects, such as roughness and scoring. If it is scored lightly, buff it with emery cloth. If the scoring is deep, replace the flywheel. Replace the pilot bearing and the clutch release bearing with the new parts in the set. Pull the old pilot bearing out and use a mallet to install the new one. Remove the clutch release bearing with a puller and use a press to install the new one. - 12
Coat the groove in the sleeve, the release lever contact surface, the pivot pin and sleeve and the contact surfaces of the release bearing with a thin coating of solid grease. Also, apply a thin coat of grease to the pressure plate wire ring, clutch cover grooves, diaphragm spring and the drive bosses on the pressure plate. - 13
Apply a thin coat of grease on the splines in the plate then slide the clutch disc onto the splines. Move it back and forth several times. Pull the disc off and wipe off any excess grease. Reassemble the clutch cover and clutch plate. Install the clutch assembly, lining up the marks on the clutch cover and the flywheel. Screw in the bolts and tighten them to 20 foot-pounds of torque. Remove the clutch alignment tool.
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