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03 lancer oz rally clutch replacement

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Old Mar 12, 2011 | 12:07 PM
  #1  
o0danxthexman0o's Avatar
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From: Gloucester, MA
03 lancer oz rally clutch replacement

Ok, so the clutch on my 03 lancer oz has been making some nasty sounds when the clutch is engaged ( foot off ) and goes away when the clutch is disengaged ( foot in ). I've been told this is my throwout bearing. Drove like that for a year or so. But now the clutch is slipping and the whole thing is toast. Got a quote of $1300 from two places which seems like too much for a car with 150,000 miles. So I am thinking of picking up a clutch kit and trying to tackle the job myself. I have a decent amount of tools ( air wrench, lots of sockets, a couple jacks, and everything in between ). I've done some tricky jobs before (wheel bearings, control arms, Inner and out tie rods, calipers pads rotors, drums, alternators etc. ) but I'm definitely no profesional. So, can anyone walk me through this? Any major hurdles I will have working in my driveway? Does the engine need to be hoisted? Does the tranny need to be completely removed, will I be able to get out the flywheel for re-surfacing/replacement? Do I need to bleed the system? These are all the things I'm worried about. Any help or advice would be beyond appreciated. I'd pay for a walkthrough with a dozen or so pics! Just kidding. Thanks in advance!
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Old Mar 13, 2011 | 12:38 PM
  #2  
mci2727's Avatar
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From: Nashville, TN
I thought this step by step HBZ posted might help as well.
This is what I used to make sure I didn't forget anything.
(Include a few notes by myself)


* well to take the axles out of the tranny you need to drain the tranny fluid take off the wheels then unbolt the struts then what you wanna do is remove that huge retaining nut in the middle of the spindle (it's 1-1/4") you'll need to hold the brake down to break this nut loose, unless you have air tools
* push that side of the cv through the back of spindle so you have the cv just conected to the tranny
* get a special cv joint removal tool (prybar lol) stick it in between the tranny and cv joint making sure you dont cut the cv joint seal (becareful not to pull to hard on the cv or it WILL pull apart. Just pry it instead
* once you have the 2 cv out remove all the sensor wiring from the mounts on the tranny (ecept the speed sensor one as this is a ***** to unplug)
* take out the 2 14mm bolt thats hold int he starter
* take out the 1 10 mm bolt that holds in the speed sensor
* take off the 2 shifter cables
* then take out the 3 17mm bolts that hold on the front cross member
* remove the 14mm nut/bolt from the front motor mount
* then take out the 14mm nut/bolt from the rear motor mount
* then remove all but one top and one bottom of the 14mm bolts that hold the tranny to the motor there are some cmoing from the drivers side and some from the pasenger

* get a tranny jack (if you have one a floor jack works good )
jack it up untill it GENTLY pushes up on the tranny
* after you have it up take off the nut bolt that holds the driver side tranny mount to the case and remove the 4 nuts that hold the mount to the tranny
* lower the tranny down so it hangs
* make sure there are no wiring harnesses left atached to the tranny
* pull the tranny out tword the driver side and it should be free
it doesent take much to get the thing apart if you get a smalll pry bar in between the tranny and motor it should come out rather easy if it doesent more then likely there is a bolt you missed that you just cant see


* remove the bolts that hold the pressure plate to the flywheel
* remove the old pressure plate and disk put the new one on make sure the side of the disk that stick out farther goes twords the tranny
* put on a few of the bolts that hold the plate to the flywheel dont make em tight yet
* line up the disk with a clutch alignment took or with your eyes and finger (i dont use the tool personaly) mci2727 used a tool!
* after you line it up tighten down the bolts in the "star pattern" make sure you only tighten them to 14 +- 2 ft-lb they dont go on super tight youll break emm off
* then just put everythign back together


Pretty much covers it all.
You've got to kinda rock the tranny side to side to get the input shaft to line up right sometimes both going in and coming out.

As you can see, it's a big job.
You have to remove the tranny from the car.
Flywheel can then be unbolted from the car.
You will need to support the engine after you remove the mounts so it doesn't break anything.
You will have to bleed the clutch after install for sure.

My advice;

1: Try spending a few hours searching this forume before posting next time.

2: Either be OK with the car being on jack stands for a few days or pay someone to do it.

3: If you do it yourself, make sure you have all the parts and tools needed before you start.
This includes but is not limited to;
New slave cylinder/tob, clutch, new fluid to replace old (Royal Purple is good stuff).

4: If you have a little extra money, you should buy a light weight flywheel and ACT clutch.
The light weight flywheel really does pick up the car and ACT makes really good clutches.

5: have a buddy to help with removing and replacing the tranny.
It's not light.
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