GM Corsica/Beretta 1988-1996 Repair Guide

Clutch Assembly

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CAUTION
The clutch driven disc contains 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.

REMOVAL & INSTALLATION



See Figures 1 through 15

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the vehicle, remove the hush panel.
  4.  
  5. Disconnect the clutch master cylinder push rod from the clutch pedal.
  6.  

  1. Refer to the "Transaxle, Removal and Installation" procedures in this section and remove the transaxle.
  2.  
  3. With the transaxle removed, matchmark the pressure plate and flywheel assembly to insure proper balance during reassembly.
  4.  
  5. Loosen the pressure plate-to-flywheel bolts (one turn at a time) until the spring pressure is removed.
  6.  
  7. Support the pressure plate and remove the bolts.
  8.  
  9. Remove the pressure plate and disc assembly; be sure to note the flywheel side of the clutch disc.
  10.  



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Fig. Fig. 1: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 2: ... then carefully removing the clutch and pressure plate assembly from the flywheel

  1. Clean and inspect the clutch assembly, flywheel, release bearing, clutch fork and pivot shaft for signs of wear. Replace any necessary parts.
  2.  



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Fig. Fig. 3: Check across the flywheel surface, it should be flat



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Fig. Fig. 4: Check the pressure plate for excessive wear



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Fig. Fig. 5: Exploded view of the clutch assembly



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Fig. Fig. 6: Release bearing removal - except Isuzu transaxle

To install:
  1. Position the clutch disc and pressure plate in the appropriate position, align the "Heavy Side" of the flywheel assembly stamped with an X with the clutch cover "Light Side" marked with paint. Support the assembly with Alignment tool No. J-290742 or equivalent.
  2.  



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Fig. Fig. 7: Install a clutch alignment arbor, to align the clutch assembly during installation

The clutch disc is installed with the damper springs offset towards the transaxle. Stamped letters on the clutch disc identify "Flywheel Side". Make sure the clutch disc is facing the same direction it was when removed. If the same pressure plate is being reused, align the marks made during the removal.



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Fig. Fig. 8: Be sure that the flywheel surface is clean, before installing the clutch

  1. Install the pressure plate-to-flywheel retaining bolts.
  2.  
  3. For 1988-90 vehicles, tighten the flywheel-to-pressure plate bolts to 15 ft. lbs. (20 Nm)
  4.  
  5. For 1991-96 vehicles, tighten the flywheel-to-pressure plate bolts as follows:
    1. Install and lightly seat bolts 1, 2, 3 then 4, 5, 6.
    2.  
    3. Tighten bolts 1, 2, 3 to 12 ft. lbs. (16 Nm).
    4.  
    5. Tighten bolts 4, 5, 6 to 12 ft. lbs. (16 Nm).
    6.  
    7. Tighten bolts 1, 2, 3 then 4, 5, 6 to 15 ft. lbs. (20 Mm) plus 30 degree rotation.

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      Fig. Fig. 9: Tighten the clutch cover bolts in the proper sequence



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      Fig. Fig. 10: Clutch plate and pressure plate installed with the alignment arbor in place



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      Fig. Fig. 11: Pressure plate-to-flywheel bolt holes should align



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      Fig. Fig. 12: You may want to use a thread locking compound on the clutch assembly bolts



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      Fig. Fig. 13: Install the clutch assembly bolts and tighten in steps, using an X pattern



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      Fig. Fig. 14: Be sure to use a torque wrench to tighten all bolts

    8.  

  6.  
  7. Remove the alignment tool.
  8.  
  9. Lightly lubricate the clutch fork ends. Fill the recess ends of the release bearing with grease. Lubricate the input shaft with a light coat of grease.
  10.  



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Fig. Fig. 15: Installation of the release bearing - Isuzu transaxle shown

  1. To complete the installation, reverse the removal procedures.
  2.  

The clutch lever must not be moved towards the flywheel until the transaxle is bolted to the engine. Damage to the transaxle, release bearing and clutch fork could occur if this is not followed.

  1. Bleed the clutch system and check the clutch operation when finished.
  2.  

 
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