Clutch Replacement

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Mark Barrett - 22 Jun 2006 21:56 GMT

I have a 95 Explorer with 245000 miles on it. My son decided to
take it four wheeling last wheel and fried the clutch while changing
gears on a steep ascent. Now both him and I will have the pleasure of
learning how to replace a clutch. I've started doing some preliminary
research and it appears a lot must come off. It starts with the clutch
master cylinder, transfer case, and transmission itself. I'm looking
for links to clutch replacement guides for this vehicle and possibly a
contact I can ask questions of as we go along. Tonight I will get the
vehicle off the ground and start looking at what we are up against.
This is a perfect car to learn on since it is not worth much but is
good for getting around in the snow and hauling a trailer.
Thanks,
Mark

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TeflonTW - 25 Jun 2006 04:26 GMT

If your 95 is anything like my 93, this job is tough. The toughest part by
far is getting the driveshaft removed. The bolts are very small (10 mm?)
and are loctited on. The small clearance means lots of turns of the wrench.

I paid $495 to a mechanic to do this job the second time. I like to work on
my truck, but... some jobs are just too exhausting.

> I have a 95 Explorer with 245000 miles on it. My son decided to
> take it four wheeling last wheel and fried the clutch while changing
[quoted text clipped - 9 lines]
> Thanks,
> Mark

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Mark Barrett - 26 Jun 2006 20:57 GMT

> If your 95 is anything like my 93, this job is tough. The toughest part by
> far is getting the driveshaft removed. The bolts are very small (10 mm?)
> and are loctited on. The small clearance means lots of turns of the wrench.

I was under my 95 last night working on taking off the exhaust
which was a slow process of applying liquid wrench and working the
bolts. I finally got them off without breaking anything.

I was looking at the drive shaft bolts and it appears a 12 pt 10mm
socket will take these off. The 12 points will fit over the star
pattern. Is this the correct tool?

I was not able to get the shift lever off. The manual says to
remove the bolt and lift the handle straight out. I removed a nut
from a bolt which appears to go through the handle from the back
and is keyed. However, the bolt does not budge. It looks to me
like the bolt should back out without screwing. What am I missing?

My son was playing in the mountains when he fried the clutch on
a steep hill. I told him the only way this car was going again was
after he and I fixed it. This is his car now.

Thanks,
Mark

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TeflonTW - 27 Jun 2006 00:22 GMT

"Mark Barrett" <markb@pogo.cos.agilent.com> wrote in message

> I was under my 95 last night working on taking off the exhaust
> which was a slow process of applying liquid wrench and working the
[quoted text clipped - 3 lines]
> socket will take these off. The 12 points will fit over the star
> pattern. Is this the correct tool?

I wasn't able to get a rachet into the tight spaces. If you can, that would
be great.

> I was not able to get the shift lever off. The manual says to
> remove the bolt and lift the handle straight out. I removed a nut
> from a bolt which appears to go through the handle from the back
> and is keyed. However, the bolt does not budge. It looks to me
> like the bolt should back out without screwing. What am I missing?

I don't remember any problem getting the shifter off. Yes, maybe you have
to kind of force it off after loosening the bolt. I just don't remember.

Everything other than the driveline bolts seemed pretty standard
maintenance.

> My son was playing in the mountains when he fried the clutch on
> a steep hill. I told him the only way this car was going again was
> after he and I fixed it. This is his car now.
>
> Thanks,
> Mark

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