Clutch Disc: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Remove the exhaust system. Refer to Exhaust System Replacement in Exhaust System.
4. Remove the driveline support assembly with the transaxle. Refer to Driveline Support Assembly Replacement (Manual Transmission).
5. Remove the engine flywheel inspection cover retaining bolts.
6. Remove the engine flywheel inspection cover from the engine flywheel housing.





7. Loosen the visible clutch pressure plate bolts.
8. Rotate the engine flywheel.
9. Repeat steps 7 and 8 until all the bolts have been loosened.
10. Remove the visible clutch pressure plate bolts.
11. Rotate the engine flywheel.
12. Repeat steps 10 and 11 until all the bolts have been removed.
13. Remove the clutch pressure plate bolts from the flywheel.
14. Remove the clutch pressure plate and the clutch driven plate.

Installation Procedure
^ Tools Required
^ J 38836 Pilot Bushing Installer/Clutch Alignment Arbor

Important: When the clutch pressure plate requires replacement; the engine flywheel must also be replaced along with the clutch pressure plate as an assembly.





1. Inspect the clutch pressure plate and the clutch driven plate for wear or damage. Repair or replace as necessary.
2. Inspect the engine flywheel. Refer to Engine Flywheel Replacement in Engine.
3. Adjust the clutch pressure plate, if necessary. Refer to Clutch Pressure Plate Adjustment (Off-Vehicle).
4. Install the clutch driven plate and clutch pressure plate to the engine flywheel.
5. Install the visible clutch pressure plate bolts finger-tight.
6. Rotate the engine flywheel.
7. Repeat steps 5 and 6 until all the bolts are installed finger-tight.
8. Using the 38836, align the clutch driven plate to the pilot bearing.

Notice: Refer to Fastener Notice in Service Precautions.





9. Tighten the clutch pressure plate bolts in the sequence shown, starting with the number one and following in numerical order.
^ Tighten the clutch pressure plate bolts in sequence and evenly over 3 increments with the fourth increment to 50 Nm (37 ft. lbs.).





10. Install the engine flywheel inspection cover.
11. Install the engine flywheel inspection cover retaining bolts.
^ Tighten the engine flywheel inspection cover retaining bolts to 25 Nm (18 ft. lbs.).
12. Install the driveline support assembly and the transaxle. Refer to Driveline Support Assembly Replacement (Manual Transmission).
13. Install the exhaust system. Refer to Exhaust System Replacement in Exhaust System.
14. Connect the negative battery cable.
^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
15. Program the transmitters. Refer to Transmitter Programming/Synchronization in Accessories and Optional Equipment.
16. Lower the vehicle.