GM Cavalier/Sunfire 1995-2000 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 15



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


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

Prior to any vehicle service that requires the removal of the actuator cylinder, the master cylinder pushrod must be disconnected from the clutch pedal. If not disconnected, permanent damage to the actuator cylinder will occur if the clutch pedal is depressed while the actuator cylinder is disconnected.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the clutch master cylinder pushrod from the clutch pedal.
  4.  
  5. Remove the transaxle.
  6.  
  7. If any of the parts are to be reused, mark the pressure plate assembly and the flywheel so they can be assembled in the same position. They were balanced as an assembly at the factory.
  8.  
  9. Loosen the attaching bolts one turn at a time until spring tension is relieved.
  10.  
  11. 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.
  12.  
  13. 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 resurfaced or replaced.
  14.  
  15. Clean the pressure plate and flywheel mating surfaces thoroughly.
  16.  

To install:
  1. Clean all parts well. Apply a small amount of high temperature grease to the pilot bearing inside the end of the crankshaft.
  2.  
  3. Position the clutch disc and pressure plate into the installed position, and support with clutch aligning 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 should be stamped Flywheel Side.
  4.  
  5. Install the pressure plate-to-flywheel bolts. Tighten them gradually in a cross pattern as follows:
    1. Install lightly seat all bolts.
    2.  
    3. Tighten bolts 1, 2, 3, then 4, 5, and 6 to 12 ft. lbs. (16 Nm).
    4.  
    5. Final torque bolts 1, 2, 3, then 4, 5, 6 to 15 ft. lbs. (20 Nm).
    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. Pack the inside recess of the release bearing completely full of chassis grease.
  10.  

Be sure the bearing pads are located on the fork ends and both spring ends are in the fork holes with the spring completely seated in bearing groove.

  1. Install the transaxle.
  2.  
  3. Install clutch master cylinder pushrod to the clutch pedal and install the retaining clip.
  4.  
  5. If equipped with cruise control, check switch adjustment at clutch pedal bracket.
  6.  

When adjusting the cruise control switch, do not exert an upward force on the clutch pedal pad of more than 20 ft. lbs. (27 Nm) or damage to the master cylinder pushrod retaining ring can result.

  1. Connect the negative battery cable.
  2.  
  3. Bleed clutch system as necessary and road test vehicle.
  4.  



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Fig. Fig. 2: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 3: ... then carefully removing the clutch and pressure plate assembly from the flywheel



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Fig. Fig. 4: Check across the flywheel surface, it should be flat



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Fig. Fig. 5: If necessary, lock the flywheel in place and remove the retaining bolts ...



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Fig. Fig. 6: ... then remove the flywheel from the crankshaft in order replace it or have it machined



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Fig. Fig. 7: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts



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Fig. Fig. 8: Check the pressure plate for excessive wear



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Fig. Fig. 9: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 10: Typical clutch alignment tool, note how the splines match the Transaxle's input shaft



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Fig. Fig. 11: Use the clutch alignment tool to align the clutch disc during assembly



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Fig. Fig. 12: Pressure plate-to-flywheel bolt holes should align



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Fig. Fig. 13: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 14: Clutch cover bolt tightening sequence



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Fig. Fig. 15: Be sure to use a torque wrench to tighten all bolts

ADJUSTMENTS



The clutch system in the General Motors J-Body vehicles is a hydraulic system and requires no adjustments. If the system is malfunctioning, use normal clutch diagnosis to determine the problem.

 
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