Derrick2k2SE

iTrader: (3)

Can anyone link to a "how to" for replacing the clutch and flywheel on an 02. I searched but couldn't find anything on clutch replacement. It really sucks we can't get a teardown manual for the 5.5 gen.

I'm figuring it's similar to any other car but I'll feel better with some step by step on my specific car.

BewstAdd1ct

R+I
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Removal

CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle from engine.
Be careful not to damage sensor edge.









Remove battery and its bracket.
Remove air duct and air cleaner box with mass air flow sensor.
Remove air breather hose.








Disconnect control cable from transaxle.
Remove control cable mounting bracket.








Remove clutch operating cylinder from transaxle.
Disconnect PNP switch, back-up lamp switch and ground harness connectors.








Remove starter motor from transaxle.
Remove crankshaft position sensor (POS) from transaxle front side.








Drain gear oil from transaxle.
Draw out drive shafts from transaxle.
Support engine of transaxle by placing a jack under oil pan. CAUTION: Do not place jack under oil pan drain plug.
Remove center member.








Remove LH mount.
Remove bolts securing transaxle.
Lower transaxle while supporting it with a jack.
Installation














Tighten LH mount and center member bolts.
Tighten clutch operating cylinder bolts.
Install drive shafts.
Tighten all transaxle bolts and any part removed.

BewstAdd1ct

Teardown
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Disassembly









Remove drain plug and filler plug.
Remove park/neutral position switch and back-up lamp switch.
After removing shift check and stopper bolt, remove control assembly.








Remove check plugs (4 pieces), check springs (4 pieces), check ***** (4 pieces) and shift check sleeve (2 pieces).








Remove transaxle case fixing bolts.
Remove bore plug. CAUTION: Be careful not to damage transaxle case.
While spreading the snap ring of mainshaft rear bearing located at bore plug hole, remove transaxle case.
Remove oil gutter, baffle plate.
Remove snap ring, mainshaft rear bearing adjusting shim and input shaft rear bearing adjusting shim from transaxle case.








Remove differential side bearing outer race (transaxle case side) and then adjusting shim.








Remove Welch plug.








Remove differential oil seal (transaxle case side).
Remove magnet from clutch housing.








With shift lever in 5th position, remove bracket bolts from reverse lever assembly. Lift reverse lever assembly to remove. CAUTION: Be careful not to lose shifter cap.
Pull out reverse fork rod then remove reverse shift fork.








Remove retaining pin of reverse bracket.
Pull out reverse bracket and reverse bracket fork rod.
Remove check ball (2 pieces) and inter lock pin.








Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of 5th & 6th shift fork using pin punch.








Remove stopper rings for 5th & 6th bracket.
Pull out 5th & 6th fork rod and remove 5th & 6th shift fork and 5th & 6th bracket.
Remove check ***** (2 pieces) and inter lock pin.








Remove retaining pin of 3rd & 4th bracket using pin punch.
Remove stopper rings for 3rd & 4th shift fork.
Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and bracket.
Remove shift check sleeve from clutch housing.








Remove retaining pin of 1st & 2nd shift fork using pin punch.
Pull out 1st & 2nd fork rod with bracket.
Remove 1st & 2nd shift fork.
Remove retaining pin of 1st & 2nd bracket using pin punch and separate fork rod and bracket.








Remove gear components from clutch housing in the following procedure.
While tapping input shaft with plastic hammer, remove input shaft assembly, mainshaft assembly and reverse idler gear assembly as a set. CAUTION: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.
Remove final drive assembly.








Remove mainshaft bearing retainer and then mainshaft front bearing.
Remove oil channel on mainshaft side.
Remove differential oil seal (clutch housing side).








Remove differential side bearing outer race (clutch housing side).








Remove input shaft oil seal. CAUTION: Be careful not to damage clutch housing.

BewstAdd1ct

reassembly
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Assembly









Using a drift, install input shaft oil seal from clutch housing end of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 inch) . CAUTION: Do not reuse oil seal.








Using a drift, install differential oil seal until the face is flush with clutch housing. CAUTION: Do not reuse oil seal.








Install oil channel on mainshaft side. CAUTION: Be careful with orientation of installation.








Using a drift, install mainshaft front bearing. CAUTION: Be careful with orientation of installation.








Install bearing retainer. CAUTION: Install with punched surface facing up.








Install differential side bearing outer race.








Install final drive assembly into clutch housing.








Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing. CAUTION: Be sure not to damage input shaft oil seal.








Install 1 et-2nd fork rod bracket onto 1st-2nd fork rod, and then install retaining pin. CAUTION: Do not reuse retaining pin.








Install 1st-2nd fork rod and 1st-2nd shift fork, and then install retaining pin. CAUTION: Do not reuse retaining pin.
Install shift check sleeve.








Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with inter lock pin.
Install stopper ring onto 3rd-4th shift fork. CAUTION: Do not reuse stopper ring.
Install retaining pin onto 3rd-4th bracket. CAUTION: Do not reuse retaining pin.
Install 2 check *****.








Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod with inter lock pin.
Install stopper ring onto 5th-6th bracket. CAUTION: Do not reuse stopper ring.








Install retaining pin onto 5th-6th shift fork. CAUTION: Do not reuse retaining pin.
Install 2 check *****.
Install reverse bracket fork rod and reverse lever bracket.
Install retaining pin onto reverse bracket. CAUTION: Do not reuse retaining pin.
Install reverse shift fork and reverse fork rod.
Install reverse lever assembly following procedures below.








Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork. CAUTION: Do not drop shifter cap.








While lifting reverse shift fork, align cam with reverse bracket.








Tighten mounting bolts to specified torque, and then install reverse lever assembly.
Install the magnet onto clutch housing.
Using a drift, install differential oil seal until it is flush with end face of transaxle case. CAUTION: Do not reuse oil seal.
Install selected input shaft adjusting shim onto input shaft.
Install baffle plate and oil gutter.
Install transaxle case following procedures below.








Install selected mainshaft rear bearing adjusting shim into transaxle case.
Temporarily install snap ring of mainshaft rear bearing into transaxle case. CAUTION: Do not reuse the snap ring.








Apply Anaerobic Liquid Gasket or equivalent to mating surfaces of transaxle case and clutch housing. CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.








With snap ring of mainshaft rear bearing temporarily installed, place transaxle case over clutch housing.








Through bore plug mounting hole, with snap ring stretched, and lift up mainshaft assembly from the control assembly mounting hole.
Securely install snap ring onto mainshaft rear bearing.








Tighten mounting bolts. Bolt A: 50.0 - 53.9 Nm (5.1 - 5.4 kgf-cm, 37 - 39 ft. lbs.) Bolt B: 63.0 - 66.9 Nm (6.5 - 6.8 kgf-cm, 47 - 49 ft. lbs.) CAUTION: Always replace bolts B as they are self-sealing bolts.
Install control assembly. CAUTION: Do not reuse the O-ring.
Install shift check and stopper bolt. CAUTION: Do not reuse shift check and stopper bolt.








Using a drift, install bore plug. CAUTION: Do not reuse bore plug.








Using a drift, install Welch plug. CAUTION: Do not reuse Welch plug.








Install 2 shift check sleeves, 4 check *****, 4 check springs, and 4 check ball plugs. CAUTION: Do not reuse check ball plug.








Apply Anaerobic Liquid Gasket or equivalent to threads of neutral switch and reverse lamp switch. Then install them into transaxle case.
Install gaskets onto drain plug and filler plug, and then install them into transaxle case. CAUTION:
Do not reuse gasket.
After oil is filled, tighten filler plug to specified torque.

BewstAdd1ct

if you need illustrations, or are replacing clearance items and require further teardown of main and countershafts or clearances for bearing replacement, etc, let me know.