A new question is answered every 9 seconds

How do you replace a clutch on a 91 ford explorer

Customer Question

I need to know how can i replace the clutch on a 91 ford explorer. The clutch is stuck and i just bought a new clutch and i want to know how to replace the old clutch with a new clutch.
Submitted: 10 years ago.
Category: Ford
Expert:  david replied 10 years ago.

  1. Remove the gearshift lever assembly from the control housing.

  2. Cover the opening in the control housing with a cloth to prevent dirt from falling into the unit.

  3. Raise the vehicle and support it safely.

  4. On 2WD vehicles, matchmark the drive shaft to the rear axle flange. Position a drain pan under the tail end of the transmission. Remove the drive shaft-to-rear axle flange fasteners and pull the drive shaft rearward to disconnect it from the transmission.

  5. Disconnect the clutch hydraulic line a the clutch housing. Plug the lines.

  6. Disconnect the speedometer from the transfer case/extension housing.

  7. Disconnect the starter motor, back-up lamp and, if equipped, neutral sensing switch harness connector.

  8. Place a wood block on a service jack and position the jack under the engine oil pan.

  9. On 4WD vehicles, remove the transfer case from the vehicle.

  10. Remove the starter motor.

  11. Position a transmission jack, under the transmission.

  12. Remove the transmission-to-engine retaining bolts and washers.

  13. Remove the nuts and bolts attaching the transmission mount and damper to the cross member.

  14. Remove the nuts and bolts attaching the cross member to the frame side rails and remove the cross member.

  15. Lower the engine jack slightly to angle the transmission assembly. Work the clutch housing off the locating dowels and slide the clutch housing and the transmission rearward until the input shaft clears the clutch disc.

  16. Lower the transmission jack and remove the transmission from the vehicle.

  1. Mark the assembled position of the pressure plate and cover the flywheel, to aid during re-assembly.

  2. Loosen the pressure plate and cover attaching bolts evenly until the pressure plate springs are expanded, and remove the bolts.

  3. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Remove the pilot bearing only for replacement.

Check the flywheel surface for flatness and, if necessary, remove it from the engine for truing

Be sure that the flywheel surface is clean before installing the clutch

Typical clutch alignment tool, note how the splines match the transmission's input shaft

Use the clutch alignment tool to align the clutch disc during assembly.

To install:

Position the clutch disc on the flywheel so that the Clutch Alignment Shaft Tool can enter the clutch pilot bearing and align the disc.

if reinstalling the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to 15-25 ft. lbs. (21-35 Nm) in the proper sequence. Remove the clutch disc pilot tool.

Ask david Your Own Question
david, Auto Service Technician
Category: Ford
Satisfied Customers: 1500
Experience:  Certified Master Technician,Certified in diesel & gasoline engines
Type Your Ford Question Here...
david is online now
How JustAnswer Works:
  • Ask an Expert
    Experts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional Answer
    Via email, text message, or notification as you wait on our site.
    Ask follow up questions if you need to.
  • 100% Satisfaction Guarantee
    Rate the answer you receive.

What Customers are Saying:

  • AlvinC answered a question about my Ford truck that only someone with an in-depth knowledge of his subject would have known what was going on. Rich D USA
< Previous | Next >
  • AlvinC answered a question about my Ford truck that only someone with an in-depth knowledge of his subject would have known what was going on. Rich D USA
  • Because of your expertise, you armed me with enough ammunition to win the battle with the dealer. They are installing a fuel filter and fuel pump at no charge to me. Molly USA
  • I needed help with my car on Saturday morning....got a response in 5 minutes, and it was the perfect solution. Thanks again to your service. Jason V. Kirkland, WA
  • I do know, after going though this with JustAnswer, that I can somewhat trust my mechanic but I will always contact you prior to going there. BR New Jersey
  • I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry. Stephanie P Elm City, NC
  • used your service this weekend with "Trecers" help. thank you ,thank you, thank you. replaced an A/C fan motor. Local Auto Zone had part. $15.00 "tracer" fee and $40.00 for parts, I saved several hundreds of dollers at a shop. i will recommend you and use you in the future. David L. Richmond, TX
  • 9 dollars, 2 hours of my time, and I drove away. Your diagnosis was right on the mark. Thank you so much. Phil Marysville, CA

JustAnswer in the News:

Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.

Meet The Experts:

  • Ron


    ASE Certified Technician

    Satisfied Customers:

    23 years with Ford specializing in drivability and electrical and AC. Ford certs and ASE Certs
< Last | Next >
  • http://ww2.justanswer.com/uploads/FO/fordguyu/2015-7-7_172556_onnieew.64x64.jpg Ron's Avatar


    ASE Certified Technician

    Satisfied Customers:

    23 years with Ford specializing in drivability and electrical and AC. Ford certs and ASE Certs
  • http://ww2.justanswer.com/uploads/MU/muddyford/2012-6-13_1204_1.64x64.png Chris (aka- Moose)'s Avatar

    Chris (aka- Moose)


    Satisfied Customers:

    16 years experience
  • http://ww2.justanswer.com/uploads/JM/jmcdo28/2012-2-23_01655_resized.64x64.jpg John Mc's Avatar

    John Mc

    Ford Technician

    Satisfied Customers:

    19 years Ford Lincoln Mercury experience
  • http://ww2.justanswer.com/uploads/wmarti7/2009-4-18_04332_Avatar.jpg Chuck's Avatar


    ASE Certified Technician

    Satisfied Customers:

    33 Years Experience,Ford Senior Master,ASE Master,L1 Advanced Engine Performance
  • http://ww2.justanswer.com/uploads/BL/Bluegorilla/2012-6-21_16298_cam.64x64.JPG Cam's Avatar


    Journeyman Automotive Technician

    Satisfied Customers:

    GM Grand Master Technician 2007. 14 years Automotive experience.
  • http://ww2.justanswer.com/uploads/CR/crzydrvr00/2013-11-3_12123_246347.64x64.jpg Richard's Avatar


    ASE Certified Technician

    Satisfied Customers:

    12 years at a Ford Lincoln/Mercury and Jaguar dealer as a technician and shop foreman.
  • http://ww2.justanswer.com/uploads/BA/baddad1/2014-4-1_23659_avatar.64x64.jpg Mike V.'s Avatar

    Mike V.

    Auto Service Technician

    Satisfied Customers:

    25 years experience on all makes and models, Licensed NYS Inspector.