GM Prizm/Nova 1985-1993 Repair Guide

Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figure 1

Do not allow grease or oil to get on any of the disc, pressure plate, or flywheel surfaces.


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 area! When cleaning clutch surfaces, use commercially available brake cleaning fluids.

  1. Remove the transaxle from the car as previously detailed.
  2.  
  3. Remove the clutch cover and disc from the bellhousing.
  4.  
  5. Unfasten the release fork bearing clips. Withdraw the release bearing hub, complete with the release bearing.
  6.  
  7. Remove the tension spring from the clutch linkage.
  8.  
  9. Remove the release fork and support.
  10.  
  11. Punch matchmarks on the clutch cover (pressure plate) and flywheel so that the pressure plate can be returned to its original position during installation.
  12.  
  13. Slowly unfasten the screws which attach the retracting springs. Loosen each screw 1 turn at a time until the tension is released.
  14.  


CAUTION
If the screws are released too quickly, the clutch assembly will fly apart, causing possible injury!

  1. Separate the pressure plate from the clutch cover/spring assembly.
  2.  
  3. Inspect the parts for wear or deterioration. It is strongly recommended that all 3 components of the clutch system-disc, pressure plate and bearing-be replaced as a unit if any part is worn. The slight additional cost of the parts is more than offset by not having to disassemble it again later on to replace another component.
  4.  
  5. Inspect the flywheel for any signs of cracking, bluing in the steel (a sign of extreme heat) or scoring. Any bluing or cracks which are found require replacement of the flywheel. While the flywheel will not be perfectly smooth, it should be free of all but the slightest ridges and valleys or scores. Any gouging deep enough to catch your fingernail during inspection requires replacement. A scored flywheel will immediately attack a new clutch disc, causing slippage and vibration.If the flywheel must be replaced, please refer to Engine & Engine Rebuilding for further directions.
  6.  

To install:
  1. When reassembling, apply a thin coating of multipurpose grease to the release bearing hub and release fork contact points. Also, pack the groove inside the clutch hub with multipurpose grease and lubricate the pivot points of the release fork.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Always use a pilot tool when installing the clutch assembly

  1. Align the matchmarks on the clutch cover and flywheel which were made during disassembly. Install the clutch and pressure plate assembly and tighten the retaining bolts just finger tight.
  2.  
  3. Center the clutch disc by using a clutch pilot tool or an old input shaft. (Pilot tools are available at most automotive parts stores.) Insert the pilot into the end of the input shaft front bearing, wiggle it gently to align the clutch disc and pressure plate and tighten the retaining bolts. The bolts should be tightened in 2 or 3 steps, gradually and evenly. Final bolt torque is 14 ft. lbs.
  4.  
  5. Install the release bearing, fork and boot.
  6.  
  7. Reinstall the transaxle as outlined previously in this Section.
  8.  

 
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