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Old 06-11-2008, 11:08 PM   #11 (permalink)
Johnny Mullet
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Part #2 Trans/Clutch Removal

Ok, so lets get this transmission out now. Remember all that fun you had removing the shift rod? Get back under there and directly above it, you will see the rear mount from the firewall to the trans.

Remove the 2 lower nuts from mount (2 14MM)
Remove the bushing bolt and nut and remove that bracket piece (14 MM)
Remove the trans mount bolts and remove from trans (3 14MM)
Use the floor jack holding engine to help you.
While there, remove the one bell housing nut below starter (14 MM nut)
Get out of there and remove the rear brace where battery was (3 14MM bolts)



Before removing the rest, look on the steel coolant tube and remove the bolt going to the trans case. It's easy to miss this and you don't want to break that tube.

Under car remove bell housing flywheel plate (2 10 MM bolts)
Top of car, remove the starter (2 12 MM bolts)
Make sure you removed bell housing nut under starter on earlier step (14 MM)
Remove 3 remaining bell housing bolts (3 14 MM)
Lean over car and grab trans (like you love it) and begin carefully wiggling the trans loose from the engine and use a pry-bar to help pry away from block. Stop part way out and go back under the car and pop the other (right) axle shaft. Finish yanking and carefully set it on the ground or get help from someone if you are not as buff as me

Now remember in step #1 I mentioned jacking the car so the tire is at least 4" off the ground? If you didn't, the trans won't clear and you will have the engine on a piece of wood and be attempting to raise the car. Good luck with that.







Now it is time for the clutch. This is gravy work now. Hopefully you got all the proper parts and supplies like a brand new -=Sachs=- Clutch kit and 3 quarts of Synchromesh trans oil from Pennzoil, GM, or Castrol. The shop I work at only uses the best products and that is what I used.



Replace throwout bearing on trans side
Remove the old clutch (6 12 MM bolts)
Replace the pilot bearing from flywheel (I made a tool)
If you want to resurface, then remove the flywheel instead. I simply used a medium grit Roloc and carefully scuffed mine. These engines have like 55 HP so I am 100% sure this was sufficient.



Use the alignment tool provided with the kit and verify which way the clutch faces. Install the clutch and pressure plate and use threadlocker on the clutch bolts. Draw them down evenly and get them tight. Use torque specs if you want from a manual. As you are tightening, wiggle the guide tool and make sure clutch is centered.



This is what I have accomplished so far. My junkyard replacement trans is at the shop awaiting new axle shaft seals because I don't want any leaks at all. It is also going to get a bath in the parts washer and maybe even paint if I feel like throwing some "Kentucky Chrome" on it. I will post some installation pics possibly tomorrow or the weekend and let you all know how it goes.

There is so much more fun stuff to do to this car.

Junkyard Transmission = $250.00
Sachs Clutch kit = $90.00
Axle seals = $19.00
3 QT Synchromesh = $25.00
Silver paint = $0.00

Total cost = $384.00
Labor time = 8-10 hours

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Last edited by Johnny Mullet; 07-21-2008 at 08:48 PM..
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