Clutch Assembly Replacement LS9

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 Driveline Support Assembly 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.

Notice: 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 Driveline Support Assembly Replacement.
11. Lower the vehicle.
12. Connect the negative battery cable and tighten the cable fastener to 15 N·m (11 lb ft).

Clutch Assembly Replacement LS3/LS7

Special Tools

Warning: 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 Driveline Support Assembly 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. Mark the clutch pressure plate and flywheel with adjacent alignment marks before removing the pressure plate.



6. Loosen the visible clutch pressure plate bolts.
7. Rotate the engine flywheel.
8. Repeat steps 7 and 8 until all the bolts have been loosened.
9. Remove the visible clutch pressure plate bolts.
10. Rotate the engine flywheel.
11. Repeat steps 10 and 11 until all the bolts have been removed.
12. Remove the clutch pressure plate bolts from the flywheel.
13. Remove the clutch pressure plate and the clutch driven plate.

1. Inspect the clutch pressure plate 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. Adjust the clutch pressure plate, if necessary. Refer to Clutch Pressure Plate Adjustment.
4. If reusing the clutch pressure plate, align the previously created mark on the flywheel with the alignment mark on the pressure plate.
5. Install the clutch driven plate and clutch pressure plate to the engine flywheel.
6. Install the visible clutch pressure plate bolts finger tight.
7. Rotate the engine flywheel.
8. Repeat steps 5 and 6 until all the bolts are installed finger-tight.
9. Using the J 38836 , align the clutch driven plate to the pilot bearing.

Caution: Refer to Fastener Caution in the Preface section.

10. Install J 42386-A and bolts. Use one M10 1.5 X 120 mm and one M10 1.5 X 45 mm bolt for proper tool operation.

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




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

Tighten
Tighten the clutch pressure plate bolts in sequence and evenly over 3 increments with the fourth increment to 70 N·m (52 lb ft).




12. Install the bell housing bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

13. Install the driveline support assembly and the transaxle. Refer to Driveline Support Assembly Replacement.
14. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

15. Lower the vehicle.