Clutch: Service and Repair
Removal Procedure^ Tools Required
- J34860 Clutch Alignment Arbor
- J26900-5 Vernier Caliper
- J36660 Electronic Torque Angle Meter
- J35271 Flywheel Lock
1. Remove the manual transaxle assembly from the vehicle. Refer to Transmission Replacement in Manual Transmission/Transaxle, Service and Repair.
2. Use the J35271 in order to hold the flywheel before removing the bolts.
3. Slowly and evenly loosen the 6 clutch pressure plate cover bolts (2) until the clutch pressure plate spring tension is completely released.
4. Remove the 6 clutch pressure plate cover bolts and the pressure plate from the flywheel.
Important: Do not use solvents, mineral spirits or other cleaning agents containing alcohol on the clutch disc (1). Solvents on the clutch disc cause slipping and premature clutch wear.
5. Remove the clutch disc from the flywheel.
Important: Index the flywheel (1) in relation to the crankshaft using a china marker before removal in order to verify correct installation. Poor engine and/or transaxle balance results if the flywheel is installed in a position other than the original position.
6. Remove the 8 flywheel bolts and the flywheel from the crankshaft. Note the flywheel position on the crankshaft.
7. Clean the flywheel (2) and the clutch pressure plate-to-clutch disc (1, 3) mating surfaces of the following substances:
^ Oil
^ Grease
^ Metallic particles
8. Clean the clutch disc (1) using a clean dry cloth.
9. Inspect the flywheel (2) and the clutch pressure plate (3) for the following conditions:
^ Cracks
^ Heat checking
^ Grooves
^ Excessive wear
^ Bent or broken pressure plate spring levers
^ Weak or damaged diaphragm spring
Notice: If any of the following conditions exist, do not attempt to disassemble or repair the clutch pressure plate. If the flywheel or the clutch pressure plate appears excessively worn, replace the flywheel and/or clutch pressure plate as necessary.
10. Inspect the clutch disc for the following conditions:
^ Cracks
^ Excessive wear
^ Damaged or weak torsional springs
11. Use J26900-5 in order to measure the clutch disc (1) wear. Measure the depth of each rivet head depression (2). The following specifications are standard rivet head depth measurements:
12. Replace the clutch disc if the clutch rivet depth is less than 0.5 mm (0.02 inch).
Installation Procedure
1. Install the flywheel to the crankshaft. Align the flywheel-to-engine marks.
Notice: Do not apply an excessive amount of sealant to the flywheel retaining bolt threads. Applying too much sealant will result in the sealant overflowing the bolt seat. This could cause the bolt to break loose during vehicle operation.
2. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads (1).
Notice: Refer to Fastener Notice in Service Precautions.
3. Install the 8 flywheel retaining bolts to the crankshaft.
^ Tighten the 8 flywheel retaining bolts in the specified sequence to 88 Nm (65 ft. lbs.).
4. After the proper torque has been reached, use J36660 and retighten the flywheel bolts in the specified sequence an additional 90 degrees.
5. Install the clutch disc to the flywheel with the torsion springs offset toward the transaxle. Use J34860 in order to center and hold in place the clutch disc on the flywheel.
6. Install the clutch pressure plate to the flywheel. Secure the flywheel with 6 clutch pressure plate cover bolts.
^ Tighten the clutch pressure plate cover bolts to 23 Nm (17 ft. lbs.).
7. Remove J34860.
8. Lubricate the transaxle input shaft splines and clutch release bearing using a thin coat of wheel bearing grease GM P/N 1051344 (or equivalent).
9. Install the manual transaxle assembly into the vehicle. Refer to Transmission Replacement in Manual Transmission/Transaxle, Service and Repair.