Warning: Support the engine when removing
the transmission. Usually, the transmission
provides some support for the engine.
Removing it removes this support.
Also, use a transmission jack, Figure 7-17, to sup-
port the transmission. Never let the transmission
hang unsupported once attaching bolts connecting
the transmission to the clutch or engine are
removed. This can cause damage to the clutch disc
splines or transmission input shaft. Make sure, for
this and for other reasons, you support the transmis-
sion at all times. If a transmission were to fall, it
could cause injury or damage. Be especially careful
when lowering a transmission and transfer case
combination, as the weight of the transfer case is
usually off-center.
6. Remove as much dust as possible from inside the
bellhousing with an approved vacuum collection
system designed for use with asbestos fibers, in
particular.
Warning: Some clutch discs contain
asbestos—a powerful cancer-causing sub-
stance. Avoid breathing dust from inside
the bellhousing or clutch assembly. Do not blow dust
off these components with compressed air.
7. Remove the throwout bearing from the clutch fork. If
the clutch fork pivots on a ball stud, remove the fork
at this time. Most clutch forks are held to the ball stud
by spring clips. See Figure 7-18. In many cases, the
clutch fork can be removed by pushing (or pulling)
the inner end toward the front of the housing while
pulling the other end straight out.
8. If still in place, remove clutch housing from the back of
the engine. (Integral-type clutch housing was removed
with transmission.) To do this, remove the clutch access
cover from the front of the housing. Then, remove the
clutch housing attaching bolts (clutch housing-to-engine
bolts). Vacuum any dust inside the housing.
Note that housing removal is not necessary in every
case. In some vehicles, the clutch assembly may be
removed through an opening provided by removal of
a clutch access cover.
9. If the pressure plate assembly and flywheel do not
have dowels or offset bolt holes for alignment pur-
poses, use a punch to mark the original position of the
clutch cover relative to the flywheel. Beforehand,
vacuum any dust from the clutch. Typical punch
marks are shown in Figure 7-19.
10. Insert a pilot shaft, or clutch alignment tool, through the
clutch disc hub and into the pilot bearing, if desired. This
will keep the clutch disc from falling out of the pressure
plate assembly as the clutch cover attaching bolts (clutch
cover-to-flywheel bolts) are being removed. Note that an
old transmission input shaft makes a good pilot shaft.
138 Manual Drive Trains and Axles
Remove drive
shaft
assembly
Rear axle housing
A
B
Cap or plug
Extension
housing
Figure 7-16. The first steps to remove a clutch. A—Remove the
drive shaft assembly. B—Cap the transmission extension
housing to prevent oil loss. Oil leakage can create a safety
hazard. (Subaru)
Transmission
Transmission
jack
Figure 7-17. Transmissions are heavy. Use a transmission jack
to support and lower the transmission from the vehicle.
(Owatonna Tool)