Tools Required

1. Remove the manual transmission assembly from the vehicle. Refer to Transaxle Assembly Removal in Manual Transmission.



2. Install the J 35271 to the engine block in order to hold the flywheel stationary (2).



3. Install J 37761 to support the clutch disc during the pressure plate removal.
4. Slowly loosen the six pressure plate cover bolts (1) evenly until the pressure plate diaphragm spring tension is completely released.
5. Remove the six pressure plate cover bolts (1) and the pressure plate assembly from the flywheel.
6. Remove the clutch disc and the J 37761 from the flywheel.
7. Remove the J 35271 from the engine block.



8. Measure the flywheel (1) for runout using the J 7872 and slowly turning the flywheel (1) using a flywheel wrench. If the flywheel runout exceeds 0.1 mm (0.004 in), the flywheel (1) must be resurfaced or replaced.

Important: The flywheel should be indexed (reference marked) before removal to ensure correct installation. If the flywheel is installed in a position other than the one from which it was removed, poor engine balance may result.

9. Remove six flywheel bolts and the flywheel (1) from the crankshaft noting the flywheel position on the crankshaft.

Important: DO NOT use alcohol-based solvents or other cleaning agents on the clutch disc. Using solvents on the clutch disc may cause slipping and premature clutch wear.

10. Clean the flywheel and pressure plate-to-clutch disc mating surfaces of all oil, grease and metallic particles.
11. Clean the clutch disc using a clean, dry cloth.
12. Inspect the flywheel and pressure plate for:

•

Cracks

•	Heat checking

•	Grooves and excessive wear

•	Bent or broken pressure plate fingers

•	Weak or damaged diaphragm spring

•	If any of the above conditions exist, do not attempt to disassemble or repair the pressure plate assembly. If the flywheel or pressure plate appears excessively worn, replace the flywheel and/or pressure plate as necessary.

13. Inspect the pilot bearing for smooth rotation. If the bearing does not spin freely, replace the pilot bearing. Refer to Clutch Pilot Bearing Replacement .
14. Inspect the clutch disc for:

•

Cracks

•	Excessive wear

•	Damaged or weak torsional springs




15. Measure the clutch disc wear using the J 26900-5 and measuring the depth of each rivet head (2) depression. Standard rivet head (2) depth should measure 1.6 mm (0.06 in). If the clutch rivet (2) depth is less than 0.5 mm (0.02 in), replace the clutch disc (1).



16. Measure the clutch disc (1) for runout using the J 7872 . Place the disc (1) between two horizontal arbors and turn slowly while measuring runout. If clutch disc runout exceeds 0.8 mm (0.031 in), replace the clutch disc (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the flywheel to the crankshaft aligning index marks made during removal; secure the flywheel with six flywheel bolts.

Tighten
Tighten the flywheel bolts to 78 N·m (56 lb ft).




2. Install the J 35271 to the engine block in order to hold the flywheel stationary.

Important: When installing the clutch disc, make sure the torsional springs are offset to the rear facing the transmission.




3. Install the clutch disc to the flywheel using the J 37761 to center the disc on the flywheel and support the disc in place.
4. Install the pressure plate to the flywheel; secure the pressure plate with six pressure plate cover bolts (1).

Tighten
Tighten the six pressure plate bolts evenly in a diagonal pattern to prevent clutch disc distortion. Then, tighten the six bolts in the same diagonal pattern to 23 N·m (17 lb ft).

5. Remove the J 35271 from the engine block and the J 37761 from the clutch disc.
6. Lubricate the transmission input shaft splines and the clutch release bearing with a thin coat of wheel bearing lubricant GM P/N 1051344, or the equivalent.
7. Lubricate the pilot bearing with a thin coat of wheel bearing lubricant GM P/N 1051344, or the equivalent.
8. Install the manual transmission assembly into the vehicle. Refer to Transaxle Assembly Installation in Manual Transmission.