I just replaced my clutch with a valair single disk 550 ceramic clutch. the job took me about 2 hours. I used the bottle jack from my engine hoist to spread the frame for the tranny crossmember. I just used basic tools. start with removing hydrolics, and the wire on top of the trans, shifter assembly and cup holder on the inside. The top top bell housing bolts are actually easiest to remove first just break them loose with a 3/8 drive ratchet then back them out by hand or use a pnuematic ratchet. the work your way down the trans, place jack under trans, remove bolts from driveshaft carrier bearing, remove drive shaft from back of trans, remove bolts and nuts holding the crossmember to the frame, spread frame as close to the crossmember as possible. drop crossmember, slide trans back lower a little bit, slide back somemore, then lower the rest of the way. Remove clutch and fly wheel, remove pilot bearing from flywheel, have fly wheel turned at your local machine shop, (shouldnt be but $25-$30 at most if they try to charge you $50 like they did me tell them to use their own money as toilet paper and not your. while the flywheel is at the shop use 2 self tapping screws and drill them into the metal ring of the rear main seal that is in the engine already and pry it out with 2 flat head screw drivers, if this doesnt work carefully set your screw driver on the outer edge of the seal inbetween the seal and the aluminum seal housing and bend the metal part in away from the wall do this in several spots, this will lessen the resistance on the seal. be careful not to damage the housing or the crank shaft during this procedure. tap in the new seal, your seal kit should provide you with a seal driver. make sure its set the same depth all around put freshly turned flywheel on with thread lock on the bolts and torque to 139 ft lbs. tap in new pilot bearing into center of flywheel, insert clutch disk centering tool and clutch disk, then place pressure plate over the assembly and tighten the 3/8 bolts to 40 ft lbs of torque. replace throw out bearing on transmission, raise tranny to correct height make sure the bell housing bolts are lined up with the tranny plate holes, move trans foreward, double check that the bell housing is parallel to the trans plate all the way around. and slide trans foreward. the tranny should be in nutral so that you can turn the output shaft easily to align the splines. You will not be able to push the trans all the way foreward there maybe a 1/2" gap or so. get your 4 center bolt from bell housing to trans plate and tighten them up to pull the trans the rest of the way in. finish putting the bell housing bolts in, spread frame one more time to pu the crossmember in, reinsert driveshaft into trans, bolt up the carrier bearing, reinstall the hydraulics, makesure to plug in the electrical connector on top of trans, Double check EVERYTHING go wash up really good, come back out and reinstall the shifter assembly and cup holder. fire her up and take her for a drive and follow your breakin instructions to a t!
