Replacing your clutch is often thought to be a costly and difficult task — but it doesn’t have to be. With some sockets, ratchets, and a little know-how, replacing your clutch can be a simple weekend project.
Is your engine running at higher RPM without a change in speed to show for it? Are you losing acceleration as you shift gears? Then it may be time for you to replace your clutch.
Some think of clutch replacement as an in-depth procedure that’s best left to a mechanic, but doing it yourself can save you a good deal of money — and isn’t as difficult as it seems. With the right tools for the job and some time over a weekend, replacing your clutch can bring an old car back to life. Here’s how it’s done.
What is a Clutch?
By connecting with or separating from your engine, the clutch transmits rotational energy to the transmission, enabling your car to shift gears smoothly. When a vehicle is idling, the clutch fully detaches, keeping rotational energy generated by the engine from reaching the transmission. This way, your car can keep running without being propelled forward.
Clutch Components
A clutch consists of three major components, with some important pieces that hold them together.
- Flywheel: The flywheel has a toothed gear system for engaging the starter motor and provides a smooth surface for the rest of the assembly to engage with. The inertia of the flywheel gives the engine more rotational energy.
- Clutch plate: This disc has springs that dampen vibration and enable smoother engine engagement. It’s made of a high-friction material and presses up against the flywheel.
- Pressure plate: Distinct for its finger-like springs that extend toward its center, the pressure plate compresses the clutch plate against the flywheel to engage the engine, and releases the clutch plate to change gears or stop.
There are two other important clutch components that you may need to replace: the release bearing and pilot bearing. Connecting the clutch assembly within the transmission bellhousing to the clutch linkage at the pedal, the release bearing (or throwout bearing) enables the spinning pressure plate to move against the stationary clutch fork or hydraulic slave cylinder. The pilot bearing is located in a recess at the end of the crankshaft and allows the flywheel to turn without continuing to impart energy onto the input shaft.
Tools You’ll Need
Now that you know the basic parts of your clutch, you need the tools to get the job done. Capri Tools has a wide selection of tools that no mechanic should go without, some of which are essential to replacing your clutch. Here are a few that you’re likely to need.
- Sockets
- Ratchets
- Wrenches
- Breaker bars
- Screwdrivers
- A clutch/brake bleeder
- A trolley jack
- Wheel chocks
- Jack stands or ramps
- A pilot tool, for extracting your pilot bearing
You’ll need a new clutch for a complete replacement, but sometimes your clutch parts can be salvaged by having them sent to a machine shop to mend minor surface damage or wear, which can be much cheaper than buying replacements.
Replacing Your Clutch
With a basic understanding of how it works and the right tools for the job, you’re now ready to replace your clutch. Before you begin, it’s important to consult your vehicle’s repair manual for any details specific to your make and model.
1. Preparation
To get started, elevate your car for easy access, and make sure it’s well-supported for safety. Also disconnect any wiring, vacuum lines, or speedometer cables that may be attached to your transmission, taking special care to remember where each electrical connection goes — otherwise, you may end up short-circuiting your car. Then, unbolt the shift assembly and replace any bushings for proper tension upon reassembly.
2. Drain and Loosen
To keep it from draining out of the tail shaft, drain out the transmission fluid by placing a drain pan beneath it and removing the plug. Then, using Capri Tools’ sockets and wrenches, remove the bolts that hold the driveshaft to the differential — and don’t forget to keep track of all those bolts! If your drive shaft still won’t budge, some vehicles have a middle support that must also be removed, so that may be the culprit.
3. Remove the Driveshaft
Take out the drive axle or prop shaft, carefully following your vehicle’s service manual. Removing the transmission crossmember may be difficult with the extra weight from the transmission applied to it, so place a floor jack with a cradle beneath it and raise it enough to take off the tension. Be extra careful when you remove the driveshaft, as even small dents can result in misalignment.
4. Remove the Crossmember and Transmission
Give yourself room to lower the transmission by taking out the crossmember. This is done by taking out the transmission-mount-to-crossmember bolts first, then the crossmember-to-subframe bolts, ensuring that the transmission is supported and balanced throughout. The transmission mount is an inexpensive part, so it’s often worthwhile to replace it while you’re there.
With the crossmember out of the way, you’re now ready to remove the transmission so that you can access your clutch. Carefully lowering the floor jack, stabilize the transmission and guide it away from the engine. Elevating the front of the engine can help separate it from the transmission, and once the two are apart, you can begin repairing the clutch.
5. Disassemble the Clutch
Use either a wrench or ratchet set to take off the bolts that fasten the pressure plate to the flywheel. Most bolts require 1/2 or 5/8-inch sockets and ratchets. Stubborn bolts can be dislodged with a breaker bar. Detach the pressure plate and the clutch disc from the flywheel, using a pilot tool to remove the pilot bearing from the clutch disc-flywheel assembly. Be careful when detaching these discs; they’re heavier than their size would suggest.
With all parts disassembled, here are a few things you should look for as you replace the components of your clutch:
- Burning, blue streaks, or excess wear marks on the flywheel; minor damage can be repaired with some machining, but grooves deeper than a fingernail indicate a need for replacement.
- Chipped, broken, or missing teeth along the perimeter of the surrounding ring gear
- Inadequate lubrication within the metal bearings of the pilot bearing
- Damaged or missing springs along the pressure plate
- Oil leaks
After you repair or replace any damaged components, you’re ready to reassemble your clutch and attach your transmission back to the engine. Most of this will be done by simply working in reverse (which is why organizing those bolts and taking note of those electrical connections is so important!), but remember to gently tighten the bolts attaching the clutch components in a star sequence to avoid stressing the discs disproportionally. Be sure to clean off the flywheel to ensure a strong grip, too.
Get the Right Tools for the Job
As you can see, replacing the clutch does take some skill, but it’s nothing that a DIY-pro like you can’t tackle — if you’ve got the tools to pull it off. Whether it’s wrenches, ratchets, screwdrivers, or sockets, Capri Tools has the tools you need for your clutch replacement. Try our tools today; we’ll shift your auto repairs into a whole new gear.