As some people don't have the ability to lift the car over the engine/trans unit, (you have to lift it
really high), another way to do it is to just remove the transmission.
This method is for the 2.5L. I have not used it for a 2.8L but it should work for that engine also. Just check to see if cooling hoses need to be removed in a 2.8L
Raise the car up as high as you can on two big jack stands just in front of the front cradle bolts. Put blocks in front of the front wheels. Take off the tires and then remove the rear wheels, rearbrake springs, brakes, cable mounts, and then the rear spindles. Wire the brakes up, out, and to the springs. Mark the rear spindle to shock mounting bolts with white-out so you can realign them later exactly. Pull the axles. I use a puller, but a crow bar pop will do them. Disconnect all of the trans stuff and the clutch slave cylinder, including little ground/sensor wires. Loosen the trans/engine bolts. Take off the trans/flywheel cover plate when you remove the starter. Remove the exhaust. Rig up an engine hoist from the passenger side and attach the chain to the driver's side of the motor. Take up the motor/trans's weight with the hoist. Remove the dog bone bolt on the motor and rotate the bone up and out of the way. Loosen the driver's side front and rear cradle bolts and support the driver's side of the cradle with a floor jack. Remove the motor mounts on the front and rear of the transmission. Remove the driver's side cradle bolts. Lower (sag down)the cradle on the driver's side as low as possible and move the floor jack to the bottom of the trans. Loosen the engine hoist and lower the floor jack to lean the motor down toward the driver's side. Remove the trans/motor bolts. Gently pull the trans out through the opening between the body and the cradle. I use a wood ramp (a block of wood) to allow easier moving down of the trans to the ground next to the car.
Clean the trans inside of the bell housing. I use brake parts cleaner and a brass brush. Note where the wire spring attaches to the throw out bearing fork and bearing. Remove the throw out bearing by taking off the little wire spring from the fork. Clean the throw out bearing shaft and inspect it for unevenness of wear. Sand with 400 grit sand paper to even it out if necessary. then finish it up with 1000 grit to bring back to real smoothness.
While the trans is off, inspect the clutch. I always change the clutch when this is all off as this is a real job and I don't want to change a bearing just to have to change the clutch again in 2000 miles.
Lubricate the throw out bearing and shaft with white lithium grease as shown in the instructions with the bearing and clutch. Lubricate the fork with grease where it contacts the throw out bearing.
Lift the trans back up into the bay using the ramp and raise it up with the floor jack into the right position to push it gently back onto the engine. Wiggle it until it seats and then get at least one bolt back in on the top. NEVER force the trans back onto the motor and never push on the clutch lever until the trans is bolted up completely.
Put everything back together.
I can do this job in about 3.5 hours and save myself the whole removal of the motor, although if you have a big hoist or an 'A'Frame to lift the car, it is easier to do this on the floor with the engine out.
Best to you!
Gary
