Alero, Grand Am 1999-2005

Driven Disc & Pressure Plate

Print

Removal & Installation



  1. Remove the transaxle from the vehicle.
  2.  
  3. Matchmark the clutch/pressure plate cover and flywheel, if reinstalling old parts. Insert a clutch plate alignment tool into the clutch disc hub.
  4.  
  5. Loosen the flywheel to pressure plate/cover bolts one turn at a time, (in the opposite order of the tightening sequence) until the spring pressure is relieved. Support the cover/plate assembly, then remove the pressure plate/clutch cover assembly and clutch disc from the flywheel. Note the position of the disc to the flywheel.
    NOTE
    Do NOT disassemble the clutch cover assembly.

  6.  
  7. Inspect the clutch disc, cover/pressure plate, flywheel, clutch fork, and pivot shaft assembly for scoring, cracks or heat damage. Replace if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the clutch disc, cover (pressure plate) assembly and using a suitable clutch alignment tool

  8.  

To install:

  1. Sparingly apply anti-seize compound to the input shaft and clutch disc splines. Install a new release bearing.
  2.  
  3. Align the -heavy side'' of the flywheel assembly, stamped with an -X'', with the clutch cover -light side'' marked with paint. Support with clutch alignment arbor tool J 29074 or equivalent. The clutch disc is installed with the damper spring-s offset towards the transaxle. There should be stamped letters on the clutch disc to identify the flywheel side.
  4.  
  5. Tighten the pressure plate/clutch-to-flywheel mounting bolts, in the sequence shown in the accompanying figure, gradually and evenly to 31 ft. lbs. (42 Nm).

    Click image to see an enlarged view

    Fig. Proper clutch cover bolt/pressure plate tightening sequence

  6.  
  7. Remove the clutch alignment tool.
  8.  
  9. Lightly lubricate the clutch fork ends which contact the bearing with chassis grease 1051344 or equivalent.
    1. On vehicles equipped with Isuzu transaxles, pack the inside diameter recess of the release bearing completely full with chassis grease part no. 1051344 or equivalent.
    2.  
    3. On all other manual transaxle applications, lubricate the inside diameter of the bearing with clutch bearing lubricant part no. 12345777 or equivalent.
      NOTE
      On the Isuzu transaxle, make sure the bearing pads are located on the fork ends (pads must be indexed) and both spring ends are in the fork holes with the spring completely seated in the bearing groove.

    4.  

  10.  
  11. To avoid transaxle damage, the clutch lever must not be moved toward the flywheel until the transaxle is bolted to the engine.
  12.  
  13. Install the transaxle.
  14.  
  15. Attach the clutch master cylinder pushrod to the clutch pedal, then secure with the retaining clip. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket.
    NOTE
    When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad of more than 20 lbs. (9 kg) or damage to the master cylinder pushrod retaining ring can result.

  16.  
  17. Connect the negative battery cable.
  18.  
  19. Check the clutch and reverse lights for proper operation.
  20.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Hydraulic line from the clutch actuator (slave cylinder)
     
    Transaxle from the vehicle
     

  4.  
  5. If any clutch components are to be reused, use the following procedure:
    1. Matchmark the clutch pressure plate to the flywheel. This is to retain the balance of the original parts. If all parts are to be replaced with new, this step is not necessary.
    2.  
    3. If the pressure plate is to be reused, loosen the pressure plate mounting bolts by turning each bolt 1 full turn until all the spring pressure is removed. This helps avoid warping the pressure plate.
    4.  
    5. Remove the clutch disc and pressure plate.
    6.  

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the clutch components-showing the clutch disk alignment tool



Click image to see an enlarged view

Fig. Clutch cover tightening sequence

  1. Apply a small amount of high-temperature grease to the pilot bearing as well as the tip of the transaxle input shaft and the clutch splines.
  2.  
  3. Install or connect the following:
    NOTE
    New pressure plate-to-flywheel replacement bolts are recommended.



    Clutch alignment tool into the flywheel
     
    Clutch disc onto the tool
     
    Pressure plate
     

  4.  
  5. Torque the pressure plate-to-flywheel bolts, in sequence to 12 ft. lbs. (16 Nm).
  6.  
  7. Remove the clutch alignment tool.
  8.  
  9. Lubricate the inside diameter of the actuator (slave cylinder/throw out bearing) with clutch bearing lubricant.
  10.  
  11. Install or connect the following:

    Transaxle
     
    Hydraulic line to the actuator (slave cylinder)
     
    Negative battery cable
     

  12.  
  13. Bleed the clutch hydraulic system.
  14.  
  15. Road test the vehicle to verify correct operation and easy shifting.
  16.  

 
label.common.footer.alt.autozoneLogo