GM Astro/Safari 1985-1996 Repair Guide

Clutch Disc and Pressure Plate

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See Figures 1 and 2



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Fig. Fig. 1: Typical clutch release bearing lubrication points



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Fig. Fig. 2: Exploded view of the clutch assembly

REMOVAL & INSTALLATION



See Figures 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 3: A clutch alignment arbor is used for removal or installation of the clutch and pressure plate assembly



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Fig. Fig. 4: Remove the transmission and bellhousing for access to the pressure plate



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Fig. Fig. 5: Loosen the pressure plate (clutch cover) bolts gradually and evenly in a cross-wise pattern



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Fig. Fig. 6: Removing the clutch and pressure plate



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Fig. Fig. 7: Be sure that the flywheel surface is clean of grease or contaminants, before installing the clutch



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Fig. Fig. 8: Use a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 9: Clutch plate and pressure plate installed with the alignment arbor in place


CAUTION
The clutch plate may contain asbestos, which has been determined to be a cancer causing agent. Never clean the clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Remove the transmission assembly from the vehicle. For details, please refer to the manual transmission procedure found earlier in this section.
  2.  
  3. Remove the slave cylinder attaching bolts, then position the cylinder aside.
  4.  
  5. Remove the clutch inspection cover.
  6.  
  7. Remove the retaining bolts, then remove the bellhousing.
  8.  
  9. Slide the clutch fork from the ball stud and remove the fork from the dust boot.
  10.  

The ball stud is threaded into the clutch housing and can be easily replaced.

  1. Install the Clutch Pilot tool No. J-33169 into the clutch plate to support it during removal.
  2.  
  3. The flywheel and clutch cover (pressure plate assembly) are marked with X 's for correct assembly or white painted letters, if these are not visible, scribe new matchmarks.
  4.  
  5. Gradually loosen the clutch pressure plate-to-flywheel bolts (one turn at a time) until all of the spring pressure is released.
  6.  
  7. Remove the bolts and the clutch assembly.
  8.  

The clutch pilot bearing is an oil impregnated type bearing pressed into the crankshaft. This bearing requires attention when the clutch is removed from the vehicle, at which time it should be cleaned and inspected for excessive wear or damage and should be replaced (if necessary).

  1. Inspect the flywheel for wear, scoring or damage and machine or replace, if necessary.
  2.  

To install:
  1. Crank the engine over by hand until the X-mark on the flywheel is on the bottom.
  2.  
  3. Position the clutch disc and pressure plate in the same relative location as removed and support with a clutch pilot tool.
  4.  

The clutch disc is installed with the damper springs and slinger toward the transmission.

  1. Rotate the clutch assembly until the X-marks on the flywheel and clutch cover align. Make sure the cover bolt holes are aligned with those in the flywheel.
  2.  
  3. Install the bolts, then tighten them evenly and gradually using a cross-wise pattern. Tighten the bolts evenly to 15-22 ft. lbs. (20-29 Nm). Do NOT overtighten.
  4.  
  5. Remove the clutch pilot tool.
  6.  
  7. Lubricate the ball socket on the clutch fork (using a high temperature grease) and reinstall on the ball stud.
  8.  
  9. Pack the recess on the inside of the throw out bearing collar and the throw out groove with graphite grease.
  10.  
  11. Install the bellhousing and the slave cylinder.
  12.  
  13. Install the throw out bearing on the fork. Lubricate the bearing groove (using a high temperature grease).
  14.  
  15. The balance of the installation procedure is the reverse of the removal steps. Be sure to properly tighten all fasteners including:

    Pressure plate-to-flywheel bolts: 15-22 ft. lbs. (20-30 Nm) for the 4-speed or 25-35 ft. lbs. (34-47 Nm) for the 5-speed
     
    Flywheel-to-crankshaft bolts: 60-75 ft. lbs. (81-102 Nm) for the 4-speed or 55-75 ft. lbs. (75-102 Nm) for the 5-speed
     
    Slave cylinder-to-bellhousing bolts: 10-15 ft. lbs. (14-20 Nm).
     

  16.  

  1. Install the transmission assembly.
  2.  

If installing an MR2, 4-speed transmission, lubricate and adjust the transmission shift linkages (using a high temperature grease).

 
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