GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Driven Disc and Pressure Plate/Clutch Cover and Disc

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the clutch disc and cover assembly

  1. Disconnect the negative battery cable.
  2.  
  3. If equipped with a cable clutch (1982-84 vehicles), disconnect the cable at the clutch release lever and transaxle, as outlined earlier in this section.
  4.  
  5. For 1985-94 vehicles remove the sound insulator from inside the vehicle. Disconnect the clutch master cylinder pushrod from the clutch pedal.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Disconnect the clutch actuator (slave) cylinder line - 1995-96 vehicles

  1. Remove the transaxle, as outlined earlier in this section.
  2.  
  3. Mark the pressure plate assembly and the flywheel so that they can be assembled in the same position. They were balanced as an assembly at the factory.
  4.  
  5. Loosen the attaching bolts one turn at a time until spring tension is relieved.
  6.  
  7. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc. Do not disassemble the pressure plate assembly; replace it if defective.
  8.  
  9. Inspect the flywheel, clutch disc, pressure plate, throwout bearing and the clutch fork and pivot shaft assembly for wear. Replace the parts as required. If the flywheel shows any signs of overheating, or if it is badly grooved or scored, it should be refaced or replaced.
  10.  



Click image to see an enlarged view

Fig. Fig. 3: You must follow the specified sequence when tightening the pressure plate retaining bolts

To install:
  1. Clean the pressure plate and flywheel mating surfaces thoroughly.
  2.  
  3. Position the clutch disc and pressure plate into the installed position, and support with a dummy shaft or clutch aligning tool, tool J 29074 or equivalent. The clutch plate is assembled with the damper springs offset toward the transaxle. One side of the factory supplied clutch disc is stamped "Flywheel Side".
  4.  
  5. Install the pressure plate-to-flywheel bolts. Tighten them in the sequence shown in the accompanying figure, as follows:
    1. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 12 ft. lbs. (16 Nm).
    2.  
    3. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 15-22 ft. lbs. (22-30 Nm) plus an additional 30° turn.
    4.  
    5. Remove the clutch alignment tool.
    6.  

  6.  
  7. Lubricate the outside groove and the inside recess of the release bearing with high temperature grease. Wipe off any excess. Install the release bearing.
  8.  
  9. Install the transaxle, as outlined earlier in this section.
  10.  


WARNING
When adjusting the cruise control switch, do NOT exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring may result.

  1. For 1985-94 vehicles, attach the clutch master cylinder pushrod to the clutch pedal and secure with the retaining clip. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket. Install the sound insulator.
  2.  
  3. If equipped with a cable clutch, attach the clutch cable at the transaxle and clutch release lever. Check the clutch operation by lifting the clutch pedal up to allow the mechanism to adjust the cable length. Depress the pedal slowly a few times to set the pawl into mesh with the quandrant teeth.
  4.  

ADJUSTMENTS



All 1982-84 models have a self-adjusting clutch mechanism located on the clutch pedal, eliminating the need for periodic free play adjustments. The self-adjusting mechanism should be inspected periodically as follows:

  1. Depress the clutch pedal and look for the pawl on the self-adjusting mechanism to firmly engage the teeth on the ratchet.
  2.  
  3. Release the clutch. The pawl should be lifted off of the teeth by the metal stop on the bracket.
  4.  

On 1985 and later models, the hydraulic clutch system provides automatic clutch adjustment. No adjustment of clutch linkage or pedal position is required.

 
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