The workings of a clutch are a complex yet integral part of conveying power in your vehicle. The engine's power is transferred to the transmission through the clutch, then to the transfer case, and on to the axles through the driveshaft. The flywheel and pressure plate hold the clutch in place with springs. Linkage is used between the clutch pedal and the pressure plate to disengage the clutch using a throwout bearing to press against the springs to disengage the clutch.
Lift the vehicle using a jackstands and a sturdy floor jack. Make sure vehicle is secure.
Disconnect the transmission from the motor, and carefully lower it using a trolley jack. The transfer case may upset the balance, so go slowly.
Disconnect the battery terminals, and remove the starter. Remove the throwout bearing and clutch housing. Using a white crayon or White-out, mark the position of the flywheel to clutch cover to help with installation later.
Loosen the clutch cover bolts one turn at a time in a crisscross pattern. The tension of the springs in the cover will be released slowly. Remove the bolts and clutch cover, Be careful with the clutch disc so that it does not fall. Mark the face of the disc present to assist in reassembly.
Inspect both surfaces of the flywheel and pressure plate for damage, which may include scorching, score marks, and cracks. Machining is recommended to ensure a good quality surface for the new clutch drive plate to engage, or if enough damage is present replace worn parts. You may have to remove the flywheel to have a machine shop resurface the face. If there is a pilot bushing oiling wick present on your model, remove it and place in a small container of oil.
Grease the pivot points of the throwout lever lightly using a moly-based grease.
If the oil wick is present on your vehicle, reinstall pilot bushing oiling wick now.
Slide the new clutch drive plate into place using a clutch alignment tool in the center of the flywheel. The alignment tool will keep it centered when the pressure plate is installed.
Clean the clutch cover plate and reinstall it. Install bolts finger tight all the way around. Again using a crisscross pattern, tighten the bolts to the specified torque setting, 35-45 ft-lbs.
Clean the clutch housing and reinstall the bolts to specified torque setting, 45 ft-lbs.
Check the starter motor for wear on the gears, replace if necessary, and reinstall. Using a new throwout bearing, attach it to the throwout lever. Check the transmission and transfer case for cracks in the case, clean and reinstall.
