How do you replace a clutch in a 1994 Ford Ranger?

Answer 1

Start by raising the truck as high as possible off the ground. Drain the tranmission fluid, and screw the plug back in. Unbolt the drive shaft from the axle. Remove the shifter cover. remove the shift lever (seems like it would make more to do this first but some time the drive bolts do not cooperate and you need to put it gear or put the parking brake on and off if it still works). Support the transmission with a jack. Remove the transmission mount bolts. Remove the mounting bolts from cross member. If the truck is high enough off the floor only only one side of cross member needs to be unfastened. Slowly lower the transmission. Remove the speedo cable. The slave cylinder is between trans mission and the clutch cover, surrounding the input shaft. The Hydraulic line can removed by pulling the clip out or just cut the hydraulic line and replace the throwout bearing, slave, master and lines, most of the time I replace them all. Remove the transmission. While the the trans mission is out replace the rubber plugs (dealer item) at the end of the shift rails or replace them with freeze plugs(better). remove clutch cover and clutch. IF YOU MACHINE THE FLYWHEEL AND/OR CLUTCH COVER A SHIM WITH SAME AMOUNT OF THICKNESS AS THE MATERIAL REMOVED MUST BE PLACED BETWEEN END OF THE CRANKSHAFT AND THE FLYWHEEL!!! IF YOU DONT GO TO THE DEALER AND GET THE SHIMS, THE CLUTCH WILL NOT DISENGAGE COMPLETELY. The effect is the same as starting the engine with the safety by passed and the clutch pedal not pushed in. The Mazda 5 speeds are light duty and if you use your truck as grocery hauler ATF fluid is fine. If plan on hauling the advertized 1/2 ton and or a trailer more than 10 miles at highway speeds (55mph or more) put in a bottle of lucas ATF goop or STP. When is below freezing just remember the let engine run for 2 or 3 minutes before putting it gear to warm up the Transmission Fluid or you will stress the syncronizers. You can add the MEASURED amount of fluid just before put the lever in and fasten the boot down. note that Ford used different size pilot bearings in some years. If you put in 99 trans in a 94 it has to match the diameter of the end of the input shaft or you wont get it to go in the last 1/2. If the pilot bearing is too big it will stress the input shaft bearing (94 in 99).