Express, Savana, G1500, G2500, G3500, 1998-2005

Driven Disc & Pressure Plate

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Removal & Installation



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

    Negative battery cable
     
    Slave cylinder
     
    Transmission assembly
     

  4.  
  5. Install the clutch removal tool and support the clutch assembly.
    NOTE
    Before removing the clutch from the flywheel, matchmark the flywheel, clutch cover and 1 pressure plate lug, so these parts may be assembled in their same relative positions and retain the factory balance.

  6.  
  7. Loosen the clutch plate retaining bolts slowly and evenly one at a time until all pressure is released from the pressure plate assembly.
  8.  
  9. Remove the clutch, pressure plate and removal tool. Check the flywheel for damage, repair or replace, as required.
  10.  
  11. Check the clutch assembly and flywheel for signs of wear, scoring, overheating, etc. If the clutch plate, flywheel or pressure plate is oil-soaked, inspect the engine rear main seal and the transmission input shaft seal and correct leakage as required. Replace any damaged parts.
  12.  

To install:

  1. Assemble the pressure plate and disc assembly, as required.
    NOTE
    The manufacturer recommends that new pressure plate bolts and washers be used.

  2.  
  3. Turn the flywheel until the previously applied mark is at the bottom.

    Click image to see an enlarged view

    Fig. Exploded view of the typical clutch assembly

  4.  
  5. Install or connect the following:

    Clutch disc, pressure plate and cover using a suitable clutch aligning tool
     

  6.  
  7. Turn the clutch until the matchmark on the clutch cover aligns with the mark on the flywheel.

    Attaching bolts and tighten in a crossing pattern until the spring pressure is taken up. Torque the bolts to 29 ft. lbs. (34 Nm).
     

  8.  
  9. Remove the aligning tool.
  10.  
  11. Apply high temperature grease to transmission input shaft.
  12.  
  13. Install or connect the following:

    Transmission. Torque the bell housing bolts to 35 ft. lbs. (47 Nm).
     
    Negative battery cable
     

  14.  
  15. Bleed the hydraulic system.
  16.  

 
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