GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch and Pressure Plate Replacement

Tools Required

DT 46551 (DW210-010) Clutch Center Guide

Removal Procedure

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


    Object Number: 1251799 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the transaxle from the vehicle. Refer Transmission Replacement in Manual Transmission - D16, or Transmission Replacement in Manual Transmission - Y4M.
  3. Remove the pressure plate bolts and the pressure plate.

    4. Object Number: 1251800 Size: SH

    Important: Support the pressure plate when you remove the last bolt.

  4. Remove the clutch disc from the flywheel

Inspection Procedure
Object Number: 1251802 Size: SH

Caution: Refer to Safety Glasses Caution in the Preface section.

Visual Inspection of Clutch Disc

  1. Inspect the worn or oily contamination on the clutch surface.
  2. Inspect the damaged or weakened torsion spring.
  3. Inspect for a warped or bent clutch disc. After inspection, replace the new clutch disc, if necessary.

Clutch Disc Inspection

  1. Measure the rivet head depth from the clutch disc surface.
  2. Replace the clutch disc if the measured value is below the limit.

    3. Specification
    The rivet head depth standard is 1.2 mm (0.047 in), limit is 0.5 mm (0.020 in).


Object Number: 1251803 Size: SH

Clutch Disc Runout in Rotational Direction Inspection

  1. Measure runout using the dial gage.
  2. If runout exceeds the limit, replace the clutch disc.

    3. Specification
    The disc runout limit in rotational direction - periphery - is 0.7 mm (0.028 in).


Object Number: 1251805 Size: SH

Visual Inspection of the Pressure Plate

  1. Inspect for a worn diaphragm spring finger.
  2. Inspect for a worn or cracked pressure plate surface.
  3. Inspect for the polluted face by the oil. After inspection, replace the pressure plate if necessary.

Installation Procedure

    Object Number: 1251807 Size: SH
  1. Coat the spline on the clutch disc with multi-purpose grease.
  2. Align the pressure plate and the clutch disc onto the flywheel using DT 46551 .

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the pressure plate bolts.

    4. Tighten

        • For the hydraulic clutch type, tighten the bolts to 15 N·m (11 lb ft).
        • For the cable clutch type, tighten the bolts to 18 N·m (13 lb ft).
  4. Remove DT 46551 from the clutch assembly.
  5. Install the transaxle into the vehicle. Refer to Transmission Replacement in Manual Transmission - D16 or Transmission Replacement in Manual Transmission - Y4M.
  6. Connect the negative battery cable.