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Old 11-10-2008, 05:09 PM
cougarkid's Avatar
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Default of Transmissions and Clutches

My son was coming home from school a couple of weeks ago and the clutch "went out". Began slipping and then just quit all together. Had to trailer it home form 3 1/2 hours out.

It is a '96 Eclipes 2.0L 5-spd.
We replaced the clutch/pressure plate/flywheel assembly and the throw-out bearing.

Here is what we did, hopefully I didn't leave too much out.

Put front of car up on jack stands.
Removed the battery.
Pulled tires, unbolted upper ball joists, and pulled half-shafts out of tranny.
Caught the gear lube running out.
Removed battery tray, unhooked linkage, unplugged speedo and back-up light switch.
Removed the windshield washer reservior.
Hung the rear of the engine from the lifting tabs with a hoist.
Unhooked exhaust from manifold, removed 3 rear mounts and dropped lower support.
Removed slave cylider, removed starter, unbolted tranny and pulled it out.

Bell housing was stuffed full of "friction plate" fibers. Appears the "plate" gave out. Found 1 rivet that looked as though it was pulled out. Took the tranny outside, swept it out and hosed it down. Bolted the new clutch assembly to the flex plate (took 3 turns to get the bolts right - only goes on 1 way). Put the throw-out bearing in the shaft and fork.

Lifted tranny into place from underneath, got it to hang on the input shaft and the frame. Reached in over the drivers fender and grabbed it by the sides. Moved it into place while turning the engine with a breaker bar to get the splines aligned. Once it slid in, spun in a top bolt and let it hang. (Took 3 tries, and removing the hood for working room, to get the input shaft aligned and bolted into place).

Bolted main rear mount, fire wall mount, lower support and front mount in place.
Connected linkage and speedo, added NEW lube to replace lube that ran out and installed back-up light switch.
Connected the exhaust.
Installed the strater.
Installed the slave cylinder
Rebolted the ball joints and put the tires back on.
Installed the windshield washer reservior.
Installed the battery tray and battery.
Put the hood back on.
Took the car down off the stands.
Started it up, backed it out of the gagage and went for a ride.
Runs great and no extra bolts!

Spent about 10 hours total on it over 2 days, as we were not in the biggest of hurries. Would reccomend a tranny jack, if you can get one to use. You can man handle it, as it is relatively light.

Guess we should have done this when we rebuilt the engine about 3000 miles ago.

Mike
 
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