Clutch Disc: Service and Repair

^ Tools Required:
- J 33169 Clutch Alignment Arbor
- J 36660 Torque Angle Meter

REMOVE OR DISCONNECT

CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily come in contact with "live" exposed electrical terminals, disconnect the battery negative cable assembly to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position.

1. Battery negative cable.
2. Raise and suitably support vehicle.
3. 5-speed manual transmission.
4. Flywheel housing cover bolts/screws (53).
5. Flywheel housing cover (12).
6. Flywheel housing bolts/screws (65).
7. Flywheel housing (34).
8. Clutch pressure plate and cover bolts/screws (51).
9. Clutch pressure plate (with cover) (30) and clutch driven plate (37).

Inspect
- Clutch pressure plate (with cover) (30) for wear or damage. Repair or replace as necessary.
- Clutch driven plate (37) for wear or damage. Replace as necessary.
- Engine flywheel.

INSTALL OR CONNECT

NOTICE: Always use the correct fastener in the correct location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHER WISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on the threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

1. Clutch driven plate (37) to engine flywheel (293.
2. Clutch pressure plate (with cover) (30).
3. Clutch pressure plate and cover bolts/screws (51).

Tighten
- Clutch pressure plate and cover bolts/screws (51) finger tight.

4. Align clutch driven plate (37) with pilot bearing (38) and clutch pressure plate (with cover) (30) using J 33169.

Tighten
- Clutch pressure plate and cover bolts/screws (51) to 20 Nm (15 ft. lbs.) plus 45° using J 36660 in star pattern.

5. Flywheel housing (34).
6. Flywheel housing bolts/screws (65).

Tighten
- Flywheel housing bolts/screws (65) to 95 Nm (70 ft. lbs.).

7. Flywheel housing cover (12).
8. Flywheel housing cover bolts/screws (53).

Tighten
- Flywheel housing cover bolts/screws (53) to 5 Nm (75 inch lbs.).

9. 5-speed manual transmission.
10. Lower vehicle.
11. Battery negative cable.