GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch Assembly Replacement

Tools Required
    • J 36547 Input Shaft Seal Installer
    • J 42474 (KM-735) Clutch Arbor or equivalent

Removal Procedure

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


    Object Number: 1255793 Size: SH
  1. Disconnect the negative battery cable.
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation .
  4. Remove the transaxle from the vehicle. Refer to Transmission Replacement .
  5. Remove the pressure plate bolts and the pressure plate. Support the pressure plate when removing the last bolt.

    6. Object Number: 1255794 Size: SH
  6. Remove the clutch disc.

    7. Object Number: 1255795 Size: SH
  7. Remove the release fork bolt.

    8. Object Number: 1255796 Size: SH
  8. Pull the clutch release shaft upward, out of the transaxle.

    9. Object Number: 1255797 Size: SH
  9. Remove the fork and the release bearing form the release bearing guide sleeve.

    10. Object Number: 1255798 Size: SH
  10. Remove the bolts and the release bearing guide sleeve.

    11. Object Number: 1255799 Size: SH
  11. Remove the input shaft seal from the release bearing guide sleeve.

    12. Object Number: 1255800 Size: SH
  12. Remove the O-ring from the groove in the transaxle case.

    13. Object Number: 1255801 Size: SH
  13. Remove the release lever shaft bushings.

Installation Procedure

    Object Number: 1255801 Size: SH
  1. Install the release lever shaft bushings. Coat the bushing bores with multi-purpose glass.

    2. Object Number: 1255800 Size: SH
  2. Install the O-ring into the groove in the case.

    3. Object Number: 1255802 Size: SH
  3. Install the input shaft seal into the release bearing guide sleeve. Use the J 36547 (1) with a hammer.

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


    Object Number: 1255798 Size: SH
  4. Install the release bearing guide sleeve and the bolts.

    5. Tighten
    Tighten the release bearing guide sleeve bolts to 5 N·m (44 lb in).

  5. Coat the sleeve surface with multi-purpose grease.

    6. Object Number: 1255797 Size: SH
  6. Coat the release bearing bore with multi-purpose grease.
  7. Install the release bearing, with the clutch fork, onto the release bearing guide sleeve.

    8. Object Number: 1255796 Size: SH
  8. Install the release lever shaft from the top of the transaxle. Guide the shaft through the clutch fork.

    9. Object Number: 1255795 Size: SH
  9. Align the shaft to the fork and install the bolt.

    10. Tighten
    Tighten the clutch fork-to-release lever shaft bolt to 35 N·m (26 lb ft).


    Object Number: 1255803 Size: SH
  10. Coat the spline on the clutch disc with multi-purpose grease.
  11. Align the pressure plate and the clutch disc onto the flywheel using the J 42474  (1) .
  12. Install the pressure plate bolts.

    13. Tighten
    Tighten the pressure plate-to-flywheel bolts to 15 N·m (11 lb ft).

  13. Remove the J 42474 (1).
  14. Install the transaxle into the vehicle. Refer to Transmission Replacement .
  15. Install the left front wheel. Refer to Tire and Wheel Removal and Installation .
  16. Lower the vehicle.
  17. Connect the negative battery cable.