GM Corvette 1984-1996 Repair Guide

Driven Disc and Pressure Plate

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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.

REMOVAL & INSTALLATION



1984-88 Vehicles

See Figures 1 through 10

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Support the engine assembly, then remove the transmission, as outlined earlier in this section.
  6.  
  7. Remove the slave cylinder attaching bolts.
  8.  
  9. Remove the flywheel housing.
  10.  
  11. Slide the clutch fork from the ball stud then remove the fork from the dust boot. The ball stud is threaded into the clutch housing and is easily replaced, if necessary.
  12.  
  13. Install a suitable clutch pilot tool to support the clutch assembly during removal. Look for the "X" mark or white painted letter on the clutch cover and the "X" mark on the flywheel. If you dont see any marks, matchmark the flywheel and clutch cover for proper alignment during installation.
  14.  
  15. Loosen the clutch-to-flywheel attaching bolts evenly, 1 turn at a time, until the spring pressure is released, then remove the bolts and remove the clutch and pressure plate assembly.
  16.  



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Fig. Fig. 1: Exploded view of the clutch pressure plate and related components-1984-88 vehicles



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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

  1. Inspect flywheel, clutch plate and disc for heat stress, cracks or worn parts and replace as necessary.
  2.  



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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.

To install
  1. Clean the pressure plate and flywheel face. They must be free of any oil, grease, metal deposits or burned spots.
  2.  
  3. Place the clutch disc and pressure place their approximate installed position and support them with a suitable universal alignment tool or a drive gear. The driven disc is installed with damper springs to the transmission. The flywheel side should be marked.
  4.  



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

  1. Turn the clutch assembly until the "X" mark (or other matchmark) on the cover lines up with the mark on the flywheel. Then, align the cover bolt holes to the nearest flywheel holes.
  2.  
  3. Install a bolt in every hole, then tighten them down evenly and gradually until tight, to avoid distorting the clutch.
  4.  



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Fig. Fig. 8: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 9: Be sure to use a torque wrench to tighten all bolts

  1. Remove the pilot tool.
  2.  
  3. Unhook the clutch fork and lubricate the ball socket and fork fingers at the release bearing end with a suitable high melting point grease (such as a graphite grease), then reinstall the fork on the ball stud.
  4.  
  5. Lubricate the recess on the inside of the release bearing collar and the clutch fork groove with a light coating of graphite grease.
  6.  



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Fig. Fig. 10: You may want to use a threadlocking compound on the clutch assembly bolts

  1. Install the clutch fork and dust boot into the clutch housing, then install the release bearing to the fork.
  2.  
  3. Install the flywheel housing.
  4.  
  5. Install the transmission, as outlined earlier in this section
  6.  
  7. Install the slave cylinder, and secure with the attaching bolts.
  8.  
  9. Lubricate the clutch fork pushrod ends, then connect the pushrod.
  10.  
  11. Adjust the shift linkage, as outlined earlier in this section.
  12.  

1989-96 Vehicles

See Figures 11, 12, 13 and 14

  1. Disconnect the negative battery cable, then raise and support the vehicle safely.
  2.  
  3. Remove the complete exhaust system.
  4.  
  5. Remove the transmission assembly.
  6.  
  7. Except for the VIN J and 1993-96 VIN P engines, remove the starter assembly.
  8.  
  9. Except for the VIN J engine, disconnect the ground wire attached to the left clutch housing stud.
  10.  
  11. Remove the nuts attaching the clutch slave cylinder to the housing and support the cylinder to the side. Do not allow the cylinder to hang freely.
  12.  
  13. For the VIN J engine, remove the nut retaining the left converter shield to the housing.
  14.  
  15. Remove the clutch housing cover.
  16.  
  17. Remove the bolts retaining the housing to the engine block, if applicable on the 5.7L (VIN J) engine, the right side converter heat shield.
  18.  
  19. Remove the housing by aligning the fork onto the 2 flats of the release bearing and push the fork away from the bearing with a twisting motion. Remove the clutch housing, for 5.7L (VIN P and 5) engine with magnesium housings, the aluminum spacers.
  20.  

Excessive clutch wear may require removal of the ball stud locking screw and loosening of the ball stud to disengage the fork and housing.

  1. Mark the alignment of the clutch cover and flywheel for installation purposes.
  2.  
  3. Loosen the clutch cover bolts evenly, 1 turn at a time until spring pressure is released. Failure to properly release spring pressure may result in damage to the clutch cover assembly and the flywheel.
  4.  
  5. Remove the clutch plate and disc assembly.
  6.  



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Fig. Fig. 11: Exploded view of the clutch system components-1995 5.7L (VIN J) engine shown, other engine similar



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Fig. Fig. 12: Clutch fork and ball attachment

  1. If necessary, remove the clutch release bearing as follows:
    1. Remove the clutch release bearing retainer.
    2.  
    3. Remove the clutch release bearing.
    4.  

  2.  

To install:

Before installation, lightly lubricate the release bearing as shown in the accompanying figure.



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Fig. Fig. 13: The clutch release bearing must be lubricated at the points shown before installation

  1. If removed, install the clutch release bearing and secure with the retainer. The retainer must be installed with the tangs facing away from the engine.
  2.  
  3. Inspect flywheel, clutch plate and disc for heat stress, cracks or worn parts and replace as necessary.
  4.  
  5. Install the clutch assembly using a suitable universal clutch disc alignment tool.
  6.  
  7. Be sure the marks made earlier are in alignment, then install the cover assembly-to-flywheel bolts. Tighten the bolts in the proper sequence, 1 turn at a time, until spring pressure is properly attained and the bolts are tightened to 30 ft. lbs. (41 Nm).
  8.  



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Fig. Fig. 13: The clutch pressure plate bolts must be tightened in the proper sequence

  1. Position the clutch housing to the engine block and engage the fork onto the release bearing. If equipped, be sure the aluminum spacer is in position.
  2.  
  3. Verify the housing is properly positioned on the 2 engine dowel pins, for the 5.7L (VIN J) engine, that the right converter heat shield is installed.
  4.  
  5. Tighten the clutch housing bolts to 37 ft. lbs. (50 Nm) and the ball stud to 33 ft. lbs. (45 Nm). Tighten the ball stud locking screw to 11 ft. lbs. (15 Nm) for VIN P and 5 engines or to 16 ft. lbs. (22 Nm) for VIN J engine, as applicable.
  6.  
  7. If equipped, install the ground harness connection to the housing.
  8.  
  9. Install the housing cover and tighten the bolts to 80 inch lbs. (9 Nm).
  10.  
  11. For the VIN J engine, install the left heat shield and tighten the retaining nut to 12 inch lbs. (1.4 Nm).
  12.  
  13. Install the clutch slave cylinder and tighten the retaining nuts to 19 ft. lbs. (25 Nm).
  14.  
  15. Install the transmission assembly.
  16.  
  17. Install the exhaust system and lower the vehicle.
  18.  
  19. Connect the negative battery cable and check clutch for proper operation.
  20.  

 
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