Clutch Disc and Pressure Plate

Removal

 CAUTION: The clutch pedal (7519) must be lifted to disengage the adjusting mechanism during clutch release lever cable installation. Failure to do so will result in damage to the self-adjuster mechanism.

 CAUTION: Under no circumstances should a prying instrument such as a screwdriver or a pry bar be used to install or remove the clutch release lever cable (7535) from clutch and brake pedal pivot shaft (7506) .

1. Lift clutch pedal to its uppermost position to disengage clutch and brake pedal pivot shaft . Push clutch and brake pedal pivot shaft forward, unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward. Refer to Cable Replacement, Section 08-02.

2. Raise vehicle on a hoist. Refer to Section 00-02.

3. Remove clutch release lever dust shield (7513) .

4. Disconnect clutch release lever cable from clutch release shaft (7515) .

5. Remove retaining clip and remove clutch release lever cable from flywheel housing (6392) .

6. Remove starter motor (11002) from flywheel housing .

7. Remove bolts that secure engine rear plate to front lower part of flywheel housing .

8. Remove transmission. Refer to Section 07-03. Remove bolts that retain flywheel housing to cylinder block (6010) . Move flywheel housing back just far enough to clear clutch pressure plate (7563) and remove.

9. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring is disengaged from pivot.

10. Remove clutch release hub and bearing (7548) from clutch release shaft .

11. Loosen six clutch pressure plate retaining bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate . If same clutch pressure plate is to be installed, mark clutch pressure plate and flywheel (6375) so that clutch pressure plate can be installed in its original position. Remove clutch pressure plate and clutch disc (7550) from flywheel .
    
    Clutch Disc and Pressure Plate
    
    
    
    
    
    

    Item	Part Number	Description
    1	6397	Flywheel Housing to Block Dowel (2 Req'd)
    2	—	Rear Face of Block and Flywheel (Part of 6010)
    3	7K578	Flywheel Housing to Block Dowel (3 Req'd)
    4	7548	Clutch Release Hub and Bearing
    5	7515	Clutch Release Shaft
    6	7600	Pilot Bearing (Install with Seal Toward Rear of Vehicle)
    7	7550	Clutch Disc
    8	7563	Clutch Pressure Plate
    9	7B602	Clutch Release Lever Stud
    10	34794-S2	Washer
    11	N606063-S2 57664-S2	Bolt (6 Req'd) (3.8L) Bolt (6 Req'd) (5.0L)
    12	6392	Flywheel Housing
    13	7050	Main Drive Gear Bearing Retainer
    14	55981-S36M	Bolt
    15	7513	Clutch Release Lever Dust Shield (Installed After Cable Assy)
    16	N807508-S2 N602549-S2	Screw and Washer Assy (6 Req'd) (3.8L) Screw and Washer Assy (6 Req'd) (5.0L)

Installation

1. Position clutch disc and clutch pressure plate assembly on flywheel . Three flywheel housing to block dowels (6397) on flywheel must be properly aligned with clutch pressure plate . Bent, damaged or missing flywheel housing to block dowels must be replaced. Start clutch pressure plate retaining bolts but do not tighten. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.

2. Align clutch disc using proper alignment tool inserted in pilot bearing (7600) . To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight. Then tighten clutch pressure plate bolts to 16-33 Nm (12-24 lb-ft). Remove alignment tool.

3. Apply a light film of Premium Long-Life Grease XG-1-C or XG-1-K (ESA-M1C75-B) or equivalent to:
   • Outside diameter of transmission main drive gear bearing retainer (7050) .
   • Clutch release shaft and anti-rattle spring where they contact clutch release hub and bearing .
   • Clutch release bearing surface that contacts clutch pressure plate release fingers.
   • Clutch release lever stud (7B602), mating release lever pocket and cable ball pocket.

   Fill grease groove of clutch release hub and bearing with same grease. Clean all excess grease from inside bore of the clutch release hub and bearing . Otherwise, excess grease will be forced onto spline by transmission main drive gear bearing retainer , and will contaminate clutch disc .

4. Install clutch release hub and bearing to clutch release shaft .

5. Install clutch release shaft and clutch release hub and bearing to flywheel housing .

6. Inspect flywheel housing dowel holes for misalignment and wear.

7. Make certain that flywheel housing and cylinder block mounting surfaces are clean and that flywheel housing to block dowels are in good condition. Bent, damaged or missing flywheel housing to block dowels must be replaced.

8. Install flywheel housing to cylinder block . Tighten bolts to 52-74 Nm (39-54 lb-ft).

9. Install transmission/transaxle-to- flywheel housing . Refer to Section 07-03.

10. Install bolts that secure engine rear plate to front lower part of flywheel housing .

11. Connect clutch release lever cable to flywheel housing and connect retaining clip.

12. Connect clutch release lever cable to clutch release shaft . Install clutch release lever dust shield .

13. Install starter motor .

14. Lower vehicle.

15. Install clutch release lever cable by lifting clutch pedal to disengage clutch and brake pedal pivot shaft . Then, push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft . Cycle clutch pedal several times to adjust clutch release lever cable . Refer to Section 08-02.