Clutch Replace

A magnesium clutch housing may be used. On these models, aluminum spacer plates are installed between the clutch housing and engine, and the clutch housing and transmission.

1. Disconnect battery ground cable.

2. Remove exhaust system from vehicle.

3. Remove transmission from vehicle as described under " Transmission, Replace." Refer to Transmission, Replace.

4. Disconnect ground connection at left hand side of clutch housing.

5. Remove nuts attaching actuating cylinder to clutch housing then position actuating cylinder aside. Support actuating cylinder so that hydraulic hose is not damaged.

6. Remove starter motor from vehicle.

7. Remove nut attaching left hand side catalytic converter shield to converter housing.

8. Remove clutch cover from clutch housing.

9. Remove bolts attaching clutch housing to engine.

10. Remove clutch housing. Align fork with two flats on release bearing, push fork away from bearing. On some models, it may be necessary to loosen ball stud locking screw and ball stud to remove housing.

11. Place align marks on clutch cover and flywheel for use during installation.

12. Alternately and evenly loosen clutch cover to flywheel attaching bolts one turn at a time until spring tension is relieved.

13. Remove clutch cover and clutch disc.

14. Check flywheel for signs of lubricant leakage. Also check flywheel friction surfaces for burned or heat checked metal. Flywheel should be checked for internal looseness. Slight movement is normal. If any of the above conditions are present, replace flywheel. The flywheel clutch surface should not be machined.

15. Reverse procedure to install, noting the following:

a. When installing clutch cover to flywheel, align marks made during removal. When installing clutch cover attaching bolts, tighten alternately and evenly in a side to side-cross pattern. Lubricate clutch fork ball and release bearing inner and outer circumference with lubricant part No. 1052356 or equivalent.

b. Tighten clutch cover retaining bolts evenly in a diagonal pattern. On final tightening sequence, torque retaining bolts to 30 ft. lbs.

c. Torque Clutch housing to engine retaining bolts to 37 ft. lbs.