Clutch: Service and Repair

NOTE:
Determine the type of clutch in use by checking the 11th position of the Vehicle Identification Number (VIN); this is the assembly plant code. Models produced at the Toluca assembly plant are equipped with a conventional clutch and are identified by the letter T; models produced at Belvidere are equipped with a modular clutch and are identified by the letter D.

CONVENTIONAL

1. Remove transaxle as outlined under Transmission and Drivetrain/ Manual Transmission/Transaxle/ Service and Repair/ Transaxle Replacement.
2. Mark clutch cover for possible later installation.
3. Support clutch disc with clutch pilot tool No. 6724, or equivalent, during removal to prevent damage.
4. Loosen clutch cover bolts in a cross pattern about two turns at a time to prevent clutch cover damage.

Conventional Clutch Assembly:

5. Remove clutch cover and clutch plate from flywheel.
6. Reverse procedure to install, noting the following:
a. The flywheel is manufactured with a slightly tapered surface and the clutch cover may have a concave taper of 0-0.0039 inch.
b. All surfaces must be clean and free of oil or corrosion.
c. Align clutch disc to flywheel using clutch pilot tool No. 6724, or equivalent.
d. Tighten clutch cover bolts to specifications in an alternating pattern, about two turns at a time, to prevent clutch cover damage.

MODULAR

1. Remove starter as outlined in Starting and Charging/ Starting System/ Starter Motor/ Service and Repair/ Starter Replacement, then remove front and rear transaxle support brackets.
2. Remove modular clutch retaining bolts, then remove transaxle as outlined under Transmission and Drivetrain/ Manual Transmission/Transaxle/ Service and Repair/ Transaxle Replacement. Transaxle and clutch are removed as an assembly.
3. Remove modular clutch assembly from transaxle input shaft. Do not allow friction surfaces to become contaminated.
4. Reverse procedure to install, noting the following:
a. Inspect engine rear main and transaxle input shaft seals for leakage. Correct any leaks prior to installing new clutch assembly.
b. Install new clutch to driveplate bolts and tighten to specifications in an alternating pattern.