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Here's a DIY on how to replace a clutch in a v6 by pulling the engine. I know going from underneath and spliting the tranny is supposed to be easier, but I had an engine hoist, and didn't want to work under the car, so I did it this way. The pictures I have aren't great detail of every little thing you have to do, but I hit the more important parts of the install that many others dont even talk about in their write ups. Lets get started!
1 gallon Coolant
1 quart power steering fluid
Once you know you have all the tools, you can get started. Make sure you wont need to use your car for a day or two (incase you dont get done, and need a few more hours from the next day) I spent a week on mine, just doing a little every night, because I didn't have to rush it. I think that was the best part. I did this in my two car garage, so if you dont have that much room, try to find somewhere that does, because once you get the engine out, you'll want to have it away from the car...just incase. Also, this will make a mess. A lot of liquids come out when you disconnect the hoses, so you should have a drip pan ready.
First thing I did was remove the hood. Have someone hold the hood while you remove the 4 bolts, and the 2 shocks. Set the hood out of the way so you dont hit it with any tools.
This step is important, because it caused me a lot of trouble because I didn't know about it. You have to remove the underdrive crank pulley (the bolt sticks out from that pulley about an inch, which is exactly how much space I needed to get the engine to come out) Refer to my DIY on the underdrive pulley if you dont know how to get that off (http://www.cardomain.com/ride/685016/7) You will need the car jacked up later on, so when you remove the pulley, just leave it jacked up, and the wheel off.
Now its time to DISCONNECT YOUR BATTERY!!!
Next, remove your intake manifold/supercharger, and set it to the side.
Place tape, or some sort of cover over the lower intake manifold openings so nothing falls down into there.
When I removed all the wires and hoses, I didn't mark any of them. If you have a photographic memory, then you dont have to either, but if you dont think you'll remember how to put EVERYTHING back together, you should mark every wire harness and hose that you disconnect. Also, when removing bolts, nuts, and screws, you can mark them too.
Anything that you can see that attatches to the engine has to come off...coolant hoses, fuel lines, ac compressor etc. For the ac compressor, DO NOT REMOVE THE HOSES!!! You can remove the compressor without having to discharge your ac system. There are 4 bolts holding it in. 3 are easy to get to and see, but the 4th is a pain to even see. You'll need a wrench to get to it, and make sure you use the opened end of it, because there's very little room between the bolt and the hose that blocks it. The bolt doesn't need to be removed from the compressor. There is enough room to get it loosed from the engine, and the bolt will just stay in the compressor, stuck behind the hose.
Once you get all 4 bolts, just let the ac compressor sit there until you're ready to remove the engine.
You'll have to remove the alternator next. You also have to remove the wire harness from it. Once its loose you should be able to wiggle it out of the engine bay.
Remove the 6 nuts and bolts from the downpipe (dont mess up the gaskets)
Remove the starter cover, which is located at the bottom of the front header. There are 2 10mm bolts, and 1 10mm nut holding it to the starter. Remove all 3. Remove the starter. There's a nut, and a bolt holding it in. Once its removed from the tranny, remove the wire harness from it.
The next few pictures will show my car with the engine pulled already, but its to show you all the hidden things that hold the engine in when you think you have everything takin apart already...
There are 12 bolts total holding the tranny to the engine. 2 of them have a number 7 on them, they are the ones that face from the passenger side, and screw in towards the drivers side. One is towards the fron of the car, and the other is towards the back. There are 4 gold bolts at the bottom of the engine/tranny, 2 of which are holding a support bracket. 4 bolts at the top of the engine/tranny, and the 2 from the starter(a nut and a bolt)
Remove the clutch arm from the tranny, its a 12mm nut, and some washers, Just pull it straight up and out. The picture shows it already takin out, so this is what yours should look like after removing it. There's also a pin with a clip on the other side of the arm, which goes into the slave cylinder, which you can see on the right. After you remove the arm, use your fingers and twist the little gear thing (on the left) counter clockwise until it stops. This will release the throw out bearing, which will allow you to pull the engine from the tranny.
On the back of the engine, towards the bottom, behind the header, there is a bracket that holds the drivetrain
This is where the engine mount normaly is. You have to remove it, and the little bolts holding the 2 lines to the car. That way you can move them around a little if you need to, when pulling the engine.
Once all the hoses and wires are detached, you'll need to hook up the engine hoist. I used a strap with two hooks, and used these brackets to pull the engine. The back one is from my stock intake manifold.
Now, everything should be removed from the engine. Before you try to pull it out, loosen the 3 bolts on the top of the transmission mount that is on the drivers side of the car. Its the 3 bolts that attatch the mount to the car, not where they attatch to the tranny. This will allow the tranny to move enough to let the engine come out.
Once you have the engine out, move it away from the car, just incase.
There are 6 hex screws (6mm) that hold the pressure plate and clutch on.
These are on pretty tight, and are easy to strip out. I got 5 off, and the 6th stripped out. So I had to cut off the head of the bolt, and pull it off that way. Once the head was cut off, I was able to unscrew the threaded part with my fingers. I guess it was just the head that was stuck to the pressure plate. I didn't damage anything but the stock pressure plate., which doesn't matter since its being replaced.
Now, get out your new clutch. You'll see a pressure plate, the clutch, an alignment tool, and a throw out bearing.
Dont forget to break it in!
Set the new clutch up against the flywheel, making sure that the flywheel side of the clutch is facing the flywheel. Mine had a little sticker telling me what side to put it on.
Place the pressure plate up to the clutch, and insert the alignment tool, so the clutch will sit where its supposed to. There are 3 little nubs that the pressure plate line up with, you might have to knock it on with a hammer, just be careful not to bend anything. Once its sitting on the nubs, screw in the 6 hex nuts, using the star pattern while tightening them. Only do each one about 2 turns at a time, until they are all tightened down.
If you had to cut off a bolt like I had to, just go to a lowes or home depot, and get a replacement bolt, doesn't have to be hex, just as long as its the same length as the others. I got my replacement at lowes, and the size was M8 X 1.25 Just bring one of the other bolts with you so you can make sure you get what you need.
This is what you should have now
Now, the next step is what others have left out when talking about doing a clutch. I think they talk about it, but it sounds confusing, so I took some pics to help everyone else out.
This is the throw out bearing
The next pictures are dark, but you should be able to get a good idea of what im talking about...
Place the throw out bearing on the shaft in the tranny. You can see the 2 little arms on the right, which will slide over the throw out bearing, on those 2 little tabs.
Once you slide the arms into the throw out bearing "tabs", you can push it all the way towards the back of the shaft, like this
Now when you put the engine back in, the pressure plate will "click" into the throw out bearing. I ended up getting my engine all the way in, and didnt hear the click until i moved that clutch arm (from the top of the tranny, that little gear thing)
Put the engine back in
Hook everything back up, and check EVERYTHING over and over again. Especially if youre doing it at 2 in the moring like I was. My brain stopped working so I had to check everything many times, and still kept finding little things that I had missed.