How to Install a Clutch on a 1997 Ford Ranger

The 1997 Ford Ranger uses a hydraulic clutch with the slave cylinder in the shape of a bellows. The slave cylinder is inside the bellhousing, surrounding the input shaft. You would be well advised to check the fluid level in the clutch reservoir and the operation of the system prior to replacing the clutch. If it is working and the clutch is worn out, the clutch pedal will engage much higher than normal.

Things You'll Need

• Floor jack
• Jack stands
• Ratchet
• Set of sockets
• Set of wrenches
• Common screwdriver
• Phillips screwdriver
• Drip pan
• Transmission gear oil
• Small punch
• Small hammer

Instructions

1. Block the wheels so the vehicle does not roll. Remove the gearshift handle. The Ford Ranger has a top loader transmission, meaning the gearshift is fitted in the top of the transmission. Remove the cover plate around the shift boot, using a Phillips screwdriver to extract the screws. Lift the plate and the rubber boot about halfway up the gearshift handle.

2. Place the gearshift in neutral and remove the bolts holding the gearshift to the top of the transmission. Lift the gearshift straight up out of the transmission and place it aside. Raise the truck with the floor jack and place jack stands under the truck for support. Raise it high enough to remove the transmission.

3. Remove the driveshaft by taking off the nuts on the U-clamps around the rear universal joint at the pinion yoke, using a wrench. Place the drip pan under the rear tail housing and slide the driveshaft out of the transmission. Remove the two bolts in the transmission mount, using a socket and remove the two bolts and nuts on either side of the transmission crossmember.

4. Disconnect any electrical wiring plugs and the speedometer. Disconnect the hydraulic line to the slave cylinder, using a small punch and hammer to push the roll pin out of the slave cylinder block, releasing the hydraulic line.

5. Place the floor jack under the transmission and raise it enough to lift the transmission off the crossmember. Remove the crossmember and lower the transmission as far as it will go, then raise it about half the distance it dropped. Remove all the bellhousing bolts using a socket.

6. Pull the transmission out carefully, keeping it balanced on the floor jack. Let the transmission down and move it aside. Remove the pressure plate and clutch, keeping in mind that it is heavy. Inspect the flywheel for damage or scoring. If it is blue or has grooves that can be felt with your fingernail, replace the flywheel. If you don’t, you will most likely have a shaky or chattering clutch.

7. Install the clutch by using the clutch centering tool, which is provided in the clutch kit, in the center hole of the clutch. Place the tip of the tool that protrudes out the back of the clutch in the center hole of the flywheel. Make sure the springs on the clutch are facing away from the flywheel. The tip of the tool fits into the pilot bushing in the flywheel and supports the clutch. Push the clutch up against the flywheel.

8. Install the pressure plate over the clutch, making sure to align the holes in the outer rim of the pressure plate with the two alignment lugs on the flywheel. Push the pressure plate on these lugs. Insert the bolts in the pressure plate and tighten securely with a socket. Once it is tight, remove the clutch installation tool.

9. Install the new throwout bearing and slave cylinder. Unsnap the throwout bearing from the spring clips, both of which are easy to identify, and pull it off the input shaft. Pull the slave cylinder bellows off next. Install the slave cylinder bellows followed by the new throwout bearing. Make sure to locate the bearing properly and snap the retaining springs back on the bearing.

10. Place the transmission on the floor jack and raise it into position. Watch carefully, as the transmission is pushed forward, that the input shaft enters the pressure plate right in the middle of the release fingers. Install all the bolts in the bellhousing and tighten securely.

11. Raise the transmission high enough to install the crossmember under it. Install the bolts and nuts on both sides of the crossmember, securing it to the frame. Tighten the bolts with a socket and wrench. Lower the transmission on the transmission mount and insert the two bolts and tighten.

12. Plug in the wiring connectors and speedometer. Install the remainder of the parts in reverse order. Top off the transmission with gear oil when completed.