Pressure Plate, Clutch Disc and Flywheel
REMOVE OR DISCONNECT
^ Tools Required:
- J 37761 Clutch Alignment Arbor
- J 35271 Flywheel Holder
1. Manual transmission assembly from vehicle.
2. Install J 35271 to the engine block in order to hold the flywheel stationary.
3. Install J 37761 to support the clutch disc during pressure plate removal.
4. Slowly loosen the six pressure plate cover bolts evenly until pressure plate diaphragm spring tension is completely released.
5. Six pressure plate cover bolts and pressure plate assembly from flywheel.
6. Clutch disc and the J 37761 from flywheel.
7. The J 35271 from the engine block.
Measure
^ Tool Required:
- J 7872 Magnetic Base Indicator Set
^ Flywheel for runout using J 7872 and slowly turning the flywheel using a flywheel wrench. If flywheel runout exceeds 0.1 mm (0.004 inch), the flywheel must be resurfaced or replaced.
Important: The flywheel should be indexed (reference marked) before removal to ensure correct installation. If the flywheel is installed in a position other than the one from which it was removed, poor engine balance may result.
8. Six flywheel bolts and flywheel from crankshaft noting flywheel position on crankshaft.
Important: DO NOT use alcohol based solvents or other cleaning agents on the clutch disc. Using solvents on the clutch disc may cause slipping and premature clutch wear.
Clean
1. Flywheel and pressure plate-to-clutch disc mating surfaces of all oil, grease and metallic particles.
2. Clutch disc using a clean, dry cloth.
Inspect
1. Flywheel and pressure plate for:
- Cracks.
- Heat checking.
- Grooves or excessive wear.
- Bent or broken pressure plate fingers.
- Weak or damaged diaphragm spring.
If any of the above conditions exist, do not attempt to disassemble or repair the pressure plate assembly. If the flywheel or pressure plate appears excessively worn, replace the flywheel and/or pressure plate as necessary.
2. Pilot bearing for smooth rotation. If the bearing does not spin freely, replace it.
3. Clutch disc for:
- Cracks.
- Excessive wear.
- Damaged or weak torsional springs.
Measure
^ Tools Required:
- J 26900-5 Vernier Caliper
- J 7872 Magnetic Base Indicator Set
1. Clutch disc wear by using J 26900-5 and measuring the depth of each rivet head depression. Standard rivet head depth should measure 1.6 mm (0.06 inch). If the clutch rivet depth is less than 0.5 mm (0.02 inch), replace the clutch disc.
2. Clutch disc for runout using J 7872. Place the disc between two horizontal arbors and turn slowly while measuring runout. If clutch disc runout exceeds 0.8 mm (0.031 inch), replace the clutch disc.
INSTALL OR CONNECT
^ Tools Required:
- J 37761 Clutch Alignment Arbor
- J 35271 Flywheel Holder
1. Flywheel to crankshaft aligning index marks made during removal; secure with six flywheel bolts.
- Tighten flywheel bolts to 78 Nm (56 lb ft).
2. The J 35271 to the engine block in order to hold the flywheel stationary.
Important: When installing the clutch disc, make sure the torsional springs are offset to the rear facing the transmission.
3. Clutch disc to the flywheel using the J 37761 clutch alignment arbor to center the disc on the flywheel and support the disc in place.
4. Pressure plate to flywheel; secure with six pressure plate cover bolts.
- Tighten all six pressure plate cover bolts evenly in a diagonal pattern to prevent clutch disc distortion. Then, tighten all six bolts in the same diagonal pattern to 23 Nm (17 lb ft).
5. Remove the J 35271 from the engine block and the J 37761 from the clutch disc.
6. Lubricate the transmission input shaft splines and clutch release bearing with a thin coat of wheel bearing lubricant.
7. Lubricate the pilot bearing with a thin coat of wheel bearing lubricant.
8. Manual transmission assembly into vehicle.