Clutch: Service and Repair

Clutch Assembly Replacement

Special Tools

* DT-49267 - Dual Clutch Alignment Tool

* DT-50194 - Clutch Disc Alignment Tool

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure





1. Remove the manual transmission. Refer to Transmission Replacement Transmission Replacement for the Aisin AY6 transmission or Transmission Replacement Transmission Replacement for the Tremec 6-Speed transmission.

2. Remove and discard the clutch pressure plate bolts.

3. Remove the clutch pressure plate and driven disc from the dowel pins on the flywheel.

Installation Procedure

1. Inspect the engine flywheel. Replace if necessary. Refer to Engine Flywheel Replacement (Manual) Service and Repair for 6 cyl engines or Engine Flywheel Replacement for V8 engines.





2. The splined portion of the driven plate protrudes out of the plate more on one side than the other. The side that protrudes out more is the transmission side. The arrow in the graphic indicates the front of the vehicle, or flywheel side of the driven plate.





3. Install the clutch pressure plate and driven plate to the dowel pins on the flywheel.

Note:
Use NEW clutch pressure plate bolts in order to maintain proper torque. Apply red LOCTITE 242 to the threads to make certain the bolts do not come loose.

4. Install the NEW clutch pressure plate bolts finger tight.





5. Ensure all three dowel pins (1) are visibly seated through the clutch cover dowel pin alignment holes as shown.

6. On V6 models, use DT-50194 - tool or a commercially available universal clutch alignment tool to align the clutch driven plate to the clutch pilot bearing.

On V8 models, use DT-49267 - tool or a commercially available universal clutch alignment tool to align the clutch driven plate to the clutch pilot bearing.





Caution:
Refer to Fastener Caution Fastener Caution.

7. On V6 models, tighten the clutch pressure plate bolts in the sequence shown, starting with the number one and following in numerical order.

1. Tighten all the clutch pressure plate bolts in sequence and evenly to 15 Nm (11 lb ft).

2. Tighten all the clutch pressure plate bolts in sequence and evenly to 30 Nm (22 lb ft).

3. Loosen bolts (1, 2, 3) 180 degrees. Re-torque bolts (1, 2, 3) in sequence and evenly to 30 Nm (22 lb ft) plus 20 degrees.

4. Loosen bolts (4, 5, 6) 180 degrees. Re-torque bolts (4, 5, 6) in sequence and evenly to 30 Nm (22 lb ft) plus 20 degrees.

8. On V8 models, tighten the clutch pressure plate bolts in the sequence shown, starting with the number one and following in numerical order.

1. Tighten all the clutch pressure plate bolts in sequence and evenly to 15 Nm (11 lb ft).

2. Tighten all the clutch pressure plate bolts in sequence and evenly to 35 Nm (26 lb ft).

3. Tighten the bolts (1, 2, 3) in sequence and evenly to 55 Nm (41 lb ft).

4. Tighten the bolts (4, 5, 6) in sequence and evenly to 70 Nm (52 lb ft).

9. Install the manual transmission. Refer to Transmission Replacement Transmission Replacement for the Aisin AY6 transmission or Transmission Replacement Transmission Replacement for the Tremec 6-Speed transmission.