GM Full Size Vans 1987-1997 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 9


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.



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Fig. Fig. 1: Exploded view of the clutch assembly

Before removing the bell housing, the engine must be supported. This can be done by placing a hydraulic jack, with a board on top, under the oil pan.

  1. Remove the transmission.
  2.  
  3. Remove the actuator assembly.
  4.  
  5. Remove the bell housing cover.
  6.  
  7. Remove the bell housing from the engine.
  8.  
  9. Remove the throwout spring and fork.
  10.  
  11. Remove the ballstud from the bellhousing.
  12.  
  13. Install a pilot tool (an old input shaft makes a good pilot tool) to hold the clutch while you are removing it.
  14.  

Before removing the clutch from the flywheel, mark the flywheel, clutch cover and one pressure plate lug, so that these parts may be assembled in their same relative positions. They were balanced as an assembly.

  1. Loosen the clutch attaching bolts one turn at a time to prevent distortion of the clutch cover until the tension is released.
  2.  
  3. Remove the clutch pilot tool and the clutch from the vehicle.
  4.  
  5. Check the pressure plate and flywheel for signs of wear, scoring, overheating, etc. If the clutch plate, flywheel, or pressure plate is oil-soaked, inspect the engine rear main seal and the transmission input shaft seal, and correct leakage as required. Replace any damaged parts.
  6.  



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Fig. Fig. 2: Removing the clutch and pressure plate bolts



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Fig. Fig. 3: Removing the clutch and pressure plate assembly



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Fig. Fig. 4: Removing the clutch and pressure plate



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Fig. Fig. 5: Be sure that the flywheel surface is clean, before installing the clutch

To install:
  1. Install a new pilot bearing. Lubricate with a few drops of machine oil.
  2.  
  3. Install the pressure plate in the cover assembly, aligning the notch in the pressure plate with the notch in the cover flange. Install pressure plate retracting springs, lockwashers and drive strap-to-pressure plate bolts. Tighten to 11 ft. lbs. (15 Nm). The clutch is now ready to be installed.
  4.  

The manufacturer recommends that new pressure plate bolts and washers be used.

  1. Turn the flywheel until the X mark is at the bottom.
  2.  
  3. Install the clutch disc, pressure plate and cover, using an old input shaft as an aligning tool.
  4.  
  5. Turn the clutch until the X mark or painted white letter on the clutch cover aligns with the X mark on the flywheel.
  6.  
  7. Install the attaching bolts and tighten them a little at a time in a crossing pattern until the spring pressure is taken up. Tighten to 22 ft. lbs. (30 Nm) on 4.3L, 5.0L and 5.7L engines; 32 ft. lbs. (43 Nm) on 6.2L and 6.5L engines; and 24 ft. lbs. (33 Nm) on 7.4L engines.
  8.  
  9. Remove the aligning tool.
  10.  
  11. Coat the rounded end of the ballstud with high temperature wheel bearing grease.
  12.  
  13. Install the ballstud in the bellhousing. Pack the ballstud from the lubrication fitting. Coat the rounded end of the ballstud with grease.
  14.  
  15. Pack the inside recess and the outside groove of the release bearing with high temperature wheel bearing grease and install the release bearing and fork.
  16.  
  17. Install the release bearing seat and spring.
  18.  
  19. Install the clutch housing. Tighten the bolts to 29 ft. lbs. (39 Nm).
  20.  
  21. Install the cover.
  22.  
  23. Install the actuator assembly.
  24.  
  25. Install the transmission.
  26.  
  27. Bleed the hydraulic system.
  28.  



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Fig. Fig. 6: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 7: Apply a thread locking agent to clutch assembly bolts



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Fig. Fig. 8: Be sure to use a torque wrench to tighten the bolts



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Fig. Fig. 9: Grease the clutch release fork ball

 
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