MERKUR XR4Ti: Removal
- Wedge a 7" block of wood under clutch pedal to disengage clutch cable self-adjuster. Place transmission in Neutral. Disconnect battery negative cable and raise vehicle. Raise vehicle. Remove catalytic converter inlet pipe at turbocharger. Remove catalytic converter and inlet pipe as assembly.
- Mark driveshaft-to-pinion flange. Remove driveshaft bolts at pinion flange. Remove center support bearing bracket bolts. Note and retain spacers. They MUST be installed to original location and position.
- Separate driveshaft at pinion flange. Support center bearing and pull driveshaft out of transmission. Install a plug in extension housing seal to prevent fluid leakage.
- Disconnect the wiring from starter. Remove starter attaching bolts, heat shield rear support bracket and transmission brace. Remove starter motor. Remove front stabilizer bar-to-body brackets and body stiffener rod. Place wooden block between stabilizer bar and body side rail.
- Install transmission jack. Remove rear mount from transmission. Remove bolts attaching rear mount to body and remove rear mount. Loosen engine mount attaching nuts, leaving 2 or 3 threads protruding from nuts. Place block of wood against engine oil pan. Raise front of engine and lower transmission jack, until engine mount nuts contact crossmember.
- Disconnect back-up light switch and neutral safety switch. Remove shift lever attaching bolts and raise shift lever out extension housing. Remove the snap ring and pull speedometer cable out of extension housing. Remove clutch release lever cover. Disengage clutch cable from release lever.
- Remove speedometer cable routing clips bolts and position cable on left side of vehicle. Remove flywheel housing rear cover plate bolts. Remove top flywheel housing attaching bolts. Remove remaining flywheel housing attaching bolts.
- Pull transmission rearward until flywheel housing contacts the vehicle body. Raise rear of transmission and pull rearward until clear of vehicle body. Lower rear of transmission and remove transmission.CAUTION: DO NOT allow any oil or grease to contact clutch disc facing or mating surfaces. Handle disc by its edges and DO NOT touch facings.
- Mark pressure plate-to-flywheel for installation reference. Install Clutch Aligner (T71P-7137-H), to hold assembly in position during removal. Loosen pressure plate bolts alternately. Remove pressure plate and clutch disc.
- Remove flywheel bolts and remove flywheel. Use care not to drop flywheel during removal of last bolt. Using slide hammer and Pilot Bearing Puller (T58L-101-A), remove pilot bearing (if replacing).