How do you install a clutch in a 1991 Toyota 4x4?

Answer 1

I've done this job on several different Toyota trucks. With 2 people, it takes between 12-16 hours.

First, I'd recommend getting several different containers for the different bolts, to keep them all organized. After that, it goes as follows:

Raise the truck up on blocks, or on a hoist if you have one. You'll need the extra room when the transmission is coming out.

Remove both driveshafts.

Remove bellhousing bolts, and unbolt the starter from the bellhousing.

Remove the bolts that hold the clutch slave cylinder to the bellhousing.

Remove the shift levers for the transmission and transfer case.

Remove the bolts that hold the anti-sway bar to the frame.

Support the transmission and transfer case, then remove the crossmember bolts. Rolling floor jacks and some blocks of wood work well for support.

Move transmission and transfer case down and rearward, away from the engine. This exposes the clutch. I've used a pair of rolling floor jacks for this, as well as some heavy-duty cargo straps as a safety. A competent assistant goes a long way, too.

There are 6 bolts that hold the clutch and pressure plate to the flywheel. Remove those. It is a good idea to inspect the flywheel at this point, and have a machinist grind the surface if it needs it.

You should also inspect the throw-out arm. I've seen them broken before.

Installing the clutch is basically the reverse. The new clutch should include a pilot shaft for centering the clutch between the pressure plate and flywheel. It should also include a new pressure plate and throw-out bearing. Put the new pieces in, then put it all back together. Aligning the motor and transmission to each other can be frustrating and time consuming, but sometime you can get lucky on it. Leave the sway-bar unbolted until the end. Othewise, it can be difficult to work around. Good luck.