REMOVAL & INSTALLATION
See Figures 1 through 7
- Disconnect the negative battery cable for safety purposes.
- Lift the clutch pedal to its upwardmost position to disengage the pawl and quadrant. Push the quadrant forward, unhook the cable from the quadrant and allow it to slowly swing rearward.
- Raise and support the vehicle safely using jackstands. Remove the clutch release lever dust shield.
- Disconnect the cable from the release lever. Remove the retaining clip and remove the clutch cable from the flywheel housing.
- Remove the starter motor and the bolts holding the engine rear plate to the lower part of the flywheel housing.
- Remove the transmission from the vehicle. Remove the bolts attaching the flywheel housing to the engine block, then remove the flywheel housing from the vehicle.
- Remove the clutch release lever from the housing by pulling it through the window in the housing until the retainer spring is disengaged from the pivot. Remove the release bearing from the release lever.
- Loosen the pressure plate cover attaching bolts evenly, to release spring tension gradually and avoid distorting the cover. If the same pressure plate and cover are to be reinstalled, matchmark the cover and flywheel so that the pressure plate can be installed in its original position. Remove the pressure plate and clutch disc from the engine.
- Inspect the flywheel for scoring, cracks or other damage. Machine or replace as necessary. Inspect the pilot bearing for damage and free movement. Replace as necessary.
- If removed, install the flywheel. Make sure the mating surfaces of the flywheel and the crankshaft flange are clean prior to installation. Tighten the flywheel bolts to 54-64 ft. lbs. (73-87 Nm) for 3.8L and 4.6L engines, or to 75-85 ft. lbs. (102-115 Nm) for the 5.0L engine.
- Position the clutch disc and pressure plate assembly on the flywheel. The three dowel pins on the flywheel must be properly aligned with the pressure plate. Bent, damaged or missing dowels must be replaced. Start the pressure plate bolts, but do not tighten them.
- Align the clutch disc using a disc alignment tool inserted into the pilot bearing. Alternately tighten the bolts a few turns at a time, until they are all tight. Then, tighten all the bolts to 12-24 ft. lbs. (17-32 Nm) for 1994-95 models, to 20-28 ft. lbs. (27-39 Nm) for 1996-98 3.8L engines, or to 19-24 ft. lbs. (25-33 Nm) for 4.6L engines, then remove the alignment tool.
- Apply a light coat of multi-purpose grease to the release lever pivot pocket, the release lever fork and the flywheel housing pivot ball. Fill the grease groove of the release bearing hub with the same grease. Clean all excess grease from the inside bore of the bearing hub.
- Install the release bearing on the release lever and install the lever in the flywheel housing.
- Install the flywheel housing. Tighten the bolts to 38-55 ft. lbs. (52-74 Nm) on 1994-95 models, or to 28-38 ft. lbs. (38-52 Nm) on 1996-98 models.
- Install the remaining components.
- Remove the jackstands and carefully lower the vehicle.
- Install the clutch release lever cable by lifting the clutch pedal to disengage the clutch and brake pedal pivot shaft, then push the pivot shaft forward and hook the end of the clutch release cable over the rear of the pivot shaft.
- Depress and lift the clutch several times to allow the self-adjusting mechanism to properly set the free-play.
- Connect the negative battery cable, then check for proper clutch operation.
See Figures 8, 9 and 10
The clutch free-play is adjusted automatically by a built-in clutch control mechanism. This device allows the clutch controls to self-adjust during normal operation.
The system consists of a spring-loaded gear quadrant, a spring-loaded pawl and a clutch cable which is spring-loaded to preload the release lever bearing. This compensates for movement of the release lever, as the clutch disc wears. The pawl, located at the top of the clutch pedal, engages the gear quadrant when the clutch pedal is depressed and pulls the cable through its continuously adjusted stroke. Clutch cable adjustments are not required because of this feature.
The self-adjusting feature should be checked every 5,000 miles (8,000 km). This is accomplished by ensuring that the clutch pedal travels to the top of its upward position. Grasp the clutch pedal with your hand or put your foot under the clutch pedal, and pull up on the pedal until it stops. Very little effort is required (about 10 lbs./4.5 kg). Finally, depress the clutch pedal and listen for an audible "click.'' If you hear a sound, the clutch was in need of adjustment, and it has just adjusted itself.