Clutch Assembly Replacement CTS

1. Remove the manual transmission. Refer to Transmission Replacement.
2. Remove the clutch pressure plate bolts.
3. Remove the clutch pressure plate and driven disc from the dowel pins on the flywheel.

Note: When the clutch driven plate requires replacement, the engine flywheel must also be replaced along with the clutch pressure plate as an assembly.

1. The splined portion of the driven plate protrudes out of the plate more on one side than the other. The side that protrudes out more is the transmission side. The arrow in the graphic indicates the front of the vehicle, or flywheel side of the driven plate.



2. Install the clutch pressure plate and driven plate to the dowel pins on the flywheel.
3. Install the clutch pressure plate bolts finger tight.
4. Using a commercially available universal clutch alignment tool, align the clutch driven plate to the clutch pilot bearing.

Caution: Refer to Fastener Caution in the Preface section.




5. Tighten the clutch pressure plate bolts in the sequence shown, starting with the number one and following in numerical order.

5.1.	Tighten all the clutch pressure plate bolts in sequence and evenly to 30 N·m (22 lb ft).

5.2.	Loosen bolts (1, 2, 3) 180 degrees. Re-torque bolts (1, 2, 3) in sequence and evenly 30 N·m (22 lb ft).

5.3.	Loosen bolts (4, 5, 6) 180 degrees. Re-torque bolts (4, 5, 6) in sequence and evenly 30 N·m (22 lb ft).

6. Install the manual transmission. Refer to Transmission Replacement.

Clutch Assembly Replacement CTS-V

Special Tools

Caution: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the driveline support assembly with the transaxle. Refer to Front Frame Replacement.



4. Remove the bell housing bolts. The upper bolts can be accessed by lowering the engine cradle approximately 25 mm (1 in) and tipping the engine back.
5. If reusing the pressure plate assembly, place a alignment mark on the pressure plate and flyweel for proper alignment during installation.

Note: Do Not use air tools to remove the clutch pressure plate bolts.




6. Loosen the clutch pressure plate bolts using the following sequence:

6.1.	Loosen bolts 1 and 2 one full turn, then stop.

6.2.	Loosen bolts 3 and 4 one full turn, then stop.

6.3.	Loosen bolts 5 and 6 one full turn, then stop.

6.4.	Repeat steps 5.1 through 5.3 until all the bolts are loose.

7. Remove the clutch pressure plate bolts from the flywheel.
8. Remove the clutch pressure plate and the clutch driven plates.

1. Inspect the clutch pressure plates and the clutch driven plate for wear or damage. Repair or replace as necessary.
2. Inspect the engine flywheel. Refer to Engine Flywheel Replacement.
3. Using the DT-49267 , align the two clutch driven plates.

Note: Do Not use air tools to install the clutch pressure plate bolts.




4. Install the clutch driven plate and clutch pressure plate to the engine flywheel with the clutch alignment tool still installed in the clutch assembly.
5. Align the match marks on the pressure plate and flywheel, if reusing the pressure plate assembly.
6. Install the clutch pressure plate bolts finger tight.

Caution: Refer to Fastener Caution in the Preface section.

7. Install J 42386-A and bolts. Use one M10 1.5 X 25 mm and one M10 1.5 X 45 mm bolt for proper tool operation.

Tighten the J 42386-A bolts to 50 N·m (37 lb ft).




8. Tighten the clutch pressure plate bolts using the following sequence:

8.1.	Finger tighten bolts 1 and 2.

8.2.	Using a socket wrench, turn bolts 1 and  2 360 degrees.

8.3.	Finger tighten bolts  3 and 4.

8.4.	Using a socket wrench, turn bolts 3 and  4 360 degrees.

8.5.	Finger tighten bolts  5 and 6.

8.6.	Using a socket wrench, turn bolts 5 and  6 360 degrees.

8.7.	Return to bolts  1 and 2 and rotate 360 degrees.

8.8.	Return to bolts 3 and 4 and rotate 360 degrees.

8.9.	Return to bolts  5 and 6 and rotate 360 degrees.

8.10.

Repeat Steps  7.7 through 7.9 until the clutch pressure plate is flat against the flywheel

8.11.

Remove the clutch alignment tool.

8.12.

Torque the bolts to 70 N·m (52 lb ft). in the numbered sequence shown.




9. Install the bell housing bolts and tighten to 50 N·m (37 lb ft).
10. Install the driveline support assembly and the transaxle. Refer to Front Frame Replacement.
11. Lower the vehicle.
12. Connect the negative battery cable and tighten the cable fastener to 15 N·m (11 lb ft).