Clutch Assembly: Removal
- Remove spare tire and support bracket. Remove negative cable from battery. DO NOT remove positive battery cable from starter. Disconnect clutch cable return spring, lock nut, adjusting nut and outer cable retainer clip. Disconnect rubber boot.
- Disconnect speedometer cable and retainer clip at transmission. Disconnect back-up lamp switch connector, starter harness and ground cable on vehicle body. Remove starter with battery cable attached. Remove upper engine-to-transmission bolts and loosen lower nuts.
- Loosen transmission side torque rod stopper nut by .39" (10 mm) and tighten engine side nut by same amount. DO NOT move side torque rod stopper more than specification. Slightly tilt engine backward to facilitate transmission removal. On all models except 4WD, remove bolts from two places which secure gear shift system to transmission.
- On 4WD models, remove hand brake tray cover and hand brake cover. Remove rod cover. Set gear selector lever at 4WD position. Remove nut connecting gear selector rod with 4WD selector rod. Remove 2 nuts connecting 4WD selector rod and lever from plate.
- Remove boot retainer screws. Remove nut connecting gear shift lever and pull up shift lever with boot. Separate both gear selector lever and 4WD selector lever system from transmission. Disconnect oxygen sensor and harness. Use care not to strike oxygen sensor against any parts during removal.
- On all models, raise and support front end of vehicle. Remove front exhaust pipe assembly. On 4WD models, remove transmission cover. On all models, remove bolts retaining drive shaft-to-differential flange and detach rear drive shaft. DO NOT damage oil seal during drive shaft removal. Plug rear of transmission to prevent oil leakage.
- Remove stabilizer bar. Remove bolts and lower left and right transverse links. Remove clamp on left side of hand brake cable. Remove nuts from left and right transmission mounting pads. Drive spring pins from inner ends of axle shafts and discard pins. Pull wheels out until axles separate from driving splines.CAUTION: DO NOT reuse axle shaft spring pins and transverse link nuts.
- Remove nuts securing left and right transmission mount rubber cushions. Support transmission with jack and remove center crossmember. Remove remaining nuts securing transmission-to-engine. Move transmission away from engine enough to prevent main shaft from interfering with engine. Lower jack and remove transmission. Remove pressure plate mount bolts. Remove clutch assembly. See Fig 1 .