Transmission

Clutch

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

Specification
Application Metric English
Clutch Fastener 28 N.m 21 lb ft
Clutch Master Cylinder Fasteners 22 N.m 16 lb ft

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

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Adhesives, Fluids, Lubricants, and Sealers
Application Type of Material GM Part Number
Locking Agent Threadlock Refer to Electronic Parts Catalogue.
Grease Sealant Refer to Electronic Parts Catalogue.

GENERAL SPECIFICATIONS

General Specifications
Component Description Specification
Type Single plate dry disc
Outside Diameter- AWD
250 mm
applications
Outside Diameter- FWD
Clutch Driven Plate 240 mm
applications
Inside Diameter 155 mm
Thickness of disc assembly
7.8± 0.2 mm
with 10,000 N load
Clutch Pressure Plate Self-adjusting with pressed
steel cover plate and multi-
Type
fingered bevelled diaphragm
spring.

DIAGNOSTIC INFORMATION AND PROCEDURES

SYMPTOMS - CLUTCH

Strategy Based Diagnostics

Review the clutch system operations in order to familiarize yourself with the system functions. Refer to Clutch
System Description and Operation.

Visual/Physical Inspection

 Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
 Inspect the clutch master cylinder for the correct fluid level.
 Inspect the hydraulic clutch lines for dents, kinks, or other obvious damage that may affect the clutch
system operations.
 Inspect the clutch system for contamination of dirt, oil, or other substances that may affect the clutch
system operations.
 Inspect for aftermarket components and power take-off (PTO) set-ups.

Intermittent

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Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.

Symptom List

NOTE: Due to the variety of clutch options there may be components in the mechanical
diagnostic tables that are not on a particular vehicle.

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:

 Clutch Drag Hard Shifting

 Clutch Rattle
 Clutch Noisy
 Clutch Pedal Spongy Low Pedal Effort
 Clutch Pedal Hard to Push
 Clutch Vibration

CLUTCH DRAG HARD SHIFTING

Clutch Drag Hard Shifting

Cause Action
DEFINITION: The clutch does not disengage completely to allow smooth shift operations. It may cause
gear clashing while the vehicle is not moving, at idle, and shifting out of neutral, or hard shifting in and
out of gears while driving the vehicle.
Review the Symptoms - Clutch and perform the necessary inspections.
Pedal blocked from full travel 1. Inspect for obstacles that prevent the pedal from
going to the floor.
2. Clear any obstacles from under the pedal area,

Too much travel between pedal and clutch
master cylinder
Clutch pedal mounting loose
Linkage at pedal worn or damaged
Clutch master cylinder seized or binding
Air in the clutch hydraulic system
Clutch actuator cylinder seized or binding
Clutch master cylinder leaking internally
Damaged clutch assembly components
such as floor mats, damaged floor, or interior
panels.
1. Inspect the pedal for worn bushings.
2. Replace the pedal bushings if worn. Refer to
Clutch Assembly Replacement (With DT-
6263).
1. Inspect the clutch pedal mounting bracket for
loose or missing fasteners.
2. Replace or repair the fasteners. Refer to Clutch
Assembly Replacement (With DT-6263).
1. Inspect the linkage at the pedal for excessive
wear.
2. Repair or replace the linkage as required. Refer
to Clutch Assembly Replacement (With DT-
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6263).
1. Inspect the master cylinder for the piston being
able to move freely and full range of travel.
2. Replace the clutch master cylinder as required.
Refer to Clutch Master Cylinder Replacement.
Bleed the clutch hydraulic system. Refer to Hydraulic
Clutch System Bleeding.
1. Inspect the clutch actuator piston for moving
freely.
2. Replace the clutch actuator cylinder if the piston
is binding. Refer to Clutch Actuator Cylinder
Replacement.
1. Inspect for proper pedal reserve. Refer to Clutch
System Description and Operation.
1. Let up halfway on pedal.
2. Apply the pedal a few times and hold
down for 30 seconds.
3. Inspect to ensure there is still the proper
pedal reserve, without letting pedal fully
up.
2. Replace the clutch master cylinder if it will not
hold pedal reserve. Refer to Clutch Master
Cylinder Replacement.
1. Remove the clutch assembly.
2. Inspect the following clutch assembly
components for damage:
 Damaged clutch disc hub splines

Excessive side loading on the release bearing
Tight or contaminated clutch disc splines
Grease or oil contamination on the clutch discs
facing
CLUTCH RATTLE
Clutch Rattle
Cause
DEFINITION: A rattle noise coming from the clutch components with the clutch disengaged or engaged.
Review the Symptoms - Clutch and perform the necessary inspections.
Idle rattle clutch engaged
Clutch is improperly installed
Clutch disc dampener worn or damaged
Bent clutch disc
 Bent drive straps
 Broken or warped pressure plate
3. Replace the clutch assembly if any of the above
damage is found. Refer to Clutch Assembly
Replacement (With DT-6263).
1. Inspect the following clutch system components:
 Worn or damaged pilot bearing
 Excessive flywheel runout
 Excessive engine to transmission
misalignment
 Clutch actuator cylinder mounting surface
out of alignment
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2. Repair or replace any faulty components.
1. Clean the clutch disc and input shaft splines.
2. If the clutch disc will not clean, replace the
clutch assembly. Refer to Clutch Assembly
Replacement (With DT-6263).
1. Repair the oil leak.
2. Repair the grease leak.
3. Clean the clutch disc facing and the other clutch
assembly components.
4. Replace the clutch assembly if it will not clean.
Refer to Clutch Assembly Replacement (With
DT-6263).
Action
Replace the clutch disc, due to faulty dampener
springs. Refer to Clutch Assembly Replacement
(With DT-6263).
Remove the clutch and install it correctly. Refer to
Clutch Assembly Replacement (With DT-6263).
1. Inspect the clutch disc for a broken or worn
dampener.
2. Replace the clutch assembly. Refer to Clutch
Assembly Replacement (With DT-6263).
Clutch disc splines worn
CLUTCH NOISY
Clutch Noisy
Cause
DEFINITION: A growl or whine noise is coming from the clutch when engaged or disengaged.
Review the Symptoms - Clutch and perform the necessary inspections.
Release bearing damaged or worn
Clutch actuator cylinder damaged or worn
CLUTCH PEDAL SPONGY LOW PEDAL EFFORT
Clutch Pedal Spongy Low Pedal Effort
Cause
DEFINITION: The clutch pedal may feel spongy, or it requires very little effort to operate.
Review Symptoms - Clutch and perform the necessary inspections.
Air in the hydraulic system
Master cylinder fluid level low
Clutch incorrectly installed
Clutch mounting bolts loose or broken
Release bearing worn or damaged
Contaminated hydraulic fluid
1. Inspect the clutch disc hub to input shaft splines
for excessive clearance.
2. Replace the clutch assembly if the clutch splines
are worn. Refer to Clutch Assembly
Replacement (With DT-6263).
Action
Replace the release bearing. Refer to Clutch
Actuator Cylinder Replacement.
Replace the clutch actuator cylinder. Refer to Clutch
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Actuator Cylinder Replacement.
Action
Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch System Bleeding.
1. Inspect for leakage in the clutch master
cylinder, hose connections, and the clutch
actuator.
2. Repair or replace any faulty components.
Remove the clutch and install it correctly. Refer to
Clutch Assembly Replacement (With DT-6263).
1. Remove the broken bolts.
2. Replace the broken or loose bolts and tighten.
Refer to Clutch Assembly Replacement (With
DT-6263).
Replace the release bearing. Refer to Clutch
Actuator Cylinder Replacement.
1. Inspect the clutch hydraulic fluid for
contamination of water. If available, use a brake
fluid boiling point tester. Boiling point should
be above 177°C (350°F).
2. Inspect the reservoir cap for being faulty if
water is present.

CLUTCH PEDAL HARD TO PUSH
Clutch Pedal Hard to Push
Cause
DEFINITION: The clutch pedal requires high effort to operate.
Review the Symptoms - Clutch and perform the necessary inspections.
Incorrect hydraulic fluid
Contaminated hydraulic fluid
Clutch pedal binding
Kinked or damaged clutch hydraulic pipe
Clutch disc worn too thin
CLUTCH VIBRATION
3. Inspect the clutch hydraulic fluid for dirt or
debris.
4. Flush and bleed the clutch hydraulic system if
the above conditions are found. Refer to
Hydraulic Clutch System Bleeding.
5. If mineral oil was added, replace the clutch
master cylinder and clutch actuator cylinder due
to seal damage. Refer to Clutch Master
Cylinder Replacement, and Clutch Actuator
Cylinder Replacement.
Action
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1. Inspect for the correct fluid in the master
cylinder. Refer to Hydraulic Clutch System
Bleeding.
2. Replace the clutch master cylinder and clutch
actuator cylinder. Refer to Clutch Master
Cylinder Replacement, and Clutch Actuator
Cylinder Replacement.
3. Flush the hydraulic system and fill with the
correct fluid.
1. Inspect the hydraulic fluid for water.
2. Inspect the hydraulic fluid for dirt or debris.
3. Flush the hydraulic system and fill with the
correct fluid. Refer to Hydraulic Clutch
System Bleeding.
1. Inspect the pedal for binding.
2. Repair or replace the pedal. Refer to Clutch
Assembly Replacement (With DT-6263).
1. Inspect for a kinked or damaged hydraulic hose.
2. Repair or replace the clutch hydraulic hose.
Refer to Clutch Master Cylinder
Replacement.
Replace the clutch assembly. Refer to Clutch
Assembly Replacement (With DT-6263).
Clutch Vibration
Cause Action
DEFINITION: Vibration from the clutch components during disengagement or engagement.
Review the Symptoms - Clutch and perform the necessary inspections.
Clutch incorrectly installed Remove the clutch and install it correctly. Refer to
Clutch Assembly Replacement (With DT-6263).
Transmission input splines worn or damaged Inspect clutch disc splines and transmission input
splines for wear or damage.
Clutch disc facings damaged Replace the clutch assembly. Refer to Clutch
Assembly Replacement (With DT-6263).
Clutch out of balance Replace the clutch assembly. Refer to Clutch
Assembly Replacement (With DT-6263).

REPAIR INSTRUCTIONS

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BRAKE, ACCELERATOR, AND CLUTCH PEDAL REPLACEMENT

Fig. 1: Brake, Accelerator, and Clutch Pedal

Courtesy of GENERAL MOTORS COMPANY

Brake, Accelerator, and Clutch Pedal Replacement

Callout Component Name

Preliminary Procedures
 1. Remove the front floor console. Refer to Front Floor Console Replacement .
2. Remove the instrument panel lower trim panel. Refer to Instrument Panel Lower Trim Panel
Replacement - Left Side .
3. Remove the instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover
Replacement - Left Side .
4. Remove the windshield side garnish molding. Refer to Windshield Side Garnish Molding
Replacement .
5. Remove the front and rear side door sill trim.
6. Remove the 2 fasteners to the power vacuum brake booster. Refer to Power Vacuum Brake
Booster Replacement .
7. Remove the clutch master cylinder. Refer to Clutch Master Cylinder Replacement.
8. Remove the steering column. Refer to Steering Column Replacement .
9. Release the hood release handle and release the instrument panel tie bar and lift it out and secure
the tie bar approximately 40 mm out, on the left side of the car. The fasteners to the pedal assembly

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needs to be removed before the tie bar is released. Refer to Instrument Panel Tie Bar
Replacement .
Brake, Accelerator, and Clutch Pedal Assembly Fastener (Qty: 7)

CAUTION:
Refer to Fastener Caution .
1

Tighten
22 N.m (16 lb ft)
Brake, Accelerator, and Clutch Pedal

Procedure
2
1. Remove the electrical connectors.
2. Release the brake pedal from the pushrod, by pulling the pedal backwards.
3. Install the NEW click fit connector on the brake pedal arm.

CLUTCH MASTER CYLINDER RESERVOIR HOSE REPLACEMENT

Removal Procedure
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Fig. 2: View Of Radiator Surge Tank And Radiator Surge Tank Clip
Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT disconnect engine coolant hoses.

1. Remove the radiator surge tank clip (2).

2. Remove the radiator surge tank (1).

Position the radiator surge tank (1) aside.

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Fig. 3: Clutch Master Cylinder Reservoir Hose
Courtesy of GENERAL MOTORS COMPANY

NOTE: Before disconnecting the reservoir tank hose, remove the clutch/brake
fluid from the reservoir tank.

3. Remove the clutch master cylinder reservoir hose (1) from the reservoir tank and the master cylinder.

Installation Procedure
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Fig. 4: Clutch Master Cylinder Reservoir Hose
Courtesy of GENERAL MOTORS COMPANY

1. Install the clutch master cylinder reservoir hose (1) to the reservoir tank and the master cylinder.
2. Bleed the hydraulic clutch system.
3. Fill the reservoir with clutch/brake fluid up to the MAX level.
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Fig. 5: View Of Radiator Surge Tank And Radiator Surge Tank Clip
Courtesy of GENERAL MOTORS COMPANY

4. Install the radiator surge tank (1).

5. Install the radiator surge tank clip (2).

CLUTCH MASTER CYLINDER REPLACEMENT

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Fig. 6: Clutch Master Cylinder & Components
Courtesy of GENERAL MOTORS COMPANY

Clutch Master Cylinder Replacement

Callout Component Name
WARNING:
Refer to Brake Fluid Irritant Warning .

CAUTION:
Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

Preliminary Procedures

1. Remove the instrument panel lower trim panel insulator. Refer to Instrument Panel Lower Trim
Panel Insulator Replacement .
2. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement (LTG) .
Clutch Pedal Return Spring
1 Procedure
Release the spring from the underside of the clutch pedal.

Clutch Pedal Master Cylinder Rod

2 Procedure

1. Depress the clutch pedal master cylinder rod retainers.

 2. Lift the clutch pedal upwards.
3. Release the clutch pedal master cylinder rod.
Clutch Master Cylinder Fastener (Qty: 2)

CAUTION:
Refer to Fastener Caution .

Procedure
3 1. Release the retainers from the pedal housing.
2. Rotate the retainers inside the clutch pedal.
3. Remove the clutch pedal retainers.

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Tighten
22 (16 lb ft)
Clutch Master Cylinder Inlet Pipe
4 Procedure
Release the clutch master cylinder inlet pipe from the master cylinder.
Clutch Master Cylinder Outlet Pipe Retainer
5 Procedure
Lift the retainer upwards to release the clutch master cylinder outlet pipe.
Clutch Master Cylinder Modulator Outlet Pipe
6 Procedure
Release the clutch master cylinder modulator outlet pipe from the master cylinder.
Clutch Master Cylinder
7 Procedure
Bleed the hydraulic clutch. Refer to Hydraulic Clutch System Bleeding.

CLUTCH ACTUATOR CYLINDER FRONT PIPE REPLACEMENT

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .

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Fig. 7: View Of Radiator Surge Tank And Radiator Surge Tank Clip
Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT disconnect engine coolant hoses.

2. Remove the radiator surge tank clip (2).

3. Remove the radiator surge tank (1).

Position the radiator surge tank (1) aside.

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Fig. 8: Clutch Actuator Cylinder Front Pipe Retainers
Courtesy of GENERAL MOTORS COMPANY

NOTE: Before disconnecting the clutch actuator cylinder front pipe, remove the
clutch/brake fluid from the reservoir tank.

4. Remove the clutch actuator cylinder front pipe retainer (1, 4).
5. Remove the clutch actuator cylinder front pipe from the retainer (3).
6. Remove the clutch actuator cylinder front pipe (2).

Installation Procedure
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Fig. 9: Clutch Actuator Cylinder Front Pipe Retainers
Courtesy of GENERAL MOTORS COMPANY

1. Install the clutch actuator cylinder front pipe (2).

2. Install the clutch actuator cylinder front pipe to the retainer (3).
3. Install the clutch actuator cylinder front pipe retainer (1, 4).
4. Bleed the hydraulic clutch system.
5. Fill the reservoir with clutch/brake fluid up to the MAX level.
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Fig. 10: View Of Radiator Surge Tank And Radiator Surge Tank Clip
Courtesy of GENERAL MOTORS COMPANY

6. Install the radiator surge tank (1).

7. Install the radiator surge tank clip (2).
8. Install the battery tray. Refer to Battery Tray Replacement .

CLUTCH ACTUATOR CYLINDER PIPE REPLACEMENT

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement .

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Fig. 11: Clutch Actuator Pressure Line And Bolt
Courtesy of GENERAL MOTORS COMPANY

2. Detach pressure line (1) from central release and unscrew bolt (2).
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Fig. 12: Clutch Actuator Pressure Line And Retaining Clip
Courtesy of GENERAL MOTORS COMPANY

3. Remove connector for pressure line (1).

1. Remove retaining clip (2).
2. Remove connector.

NOTE: If necessary, bend squeeze together slightly.

3. Replace retaining clip in connector.

4. Remove pressure line.

NOTE: Carefully disengage retaining lugs.

1. Clip pressure line out of fastening sleeve using a screwdriver or equivalent.

2. Remove pressure line.
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Fig. 13: Slide Fastening Sleeve Upwards
Courtesy of GENERAL MOTORS COMPANY

NOTE: Fastening sleeve must be replaced after removal.

5. Remove fastening sleeve.

1. Disengage fastening sleeve (1) from clutch housing.
2. Slide fastening sleeve upwards.
3. Remove fastening sleeve.
6. Check seal ring and pressure line for damage, replace if necessary.

Installation Procedure
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Fig. 14: Fastening Sleeve And Insertion Slot Location
Courtesy of GENERAL MOTORS COMPANY

NOTE: Insert projection on sleeve in the slot provided in the transmission.

1. Attach fastening sleeve (1). Push into transmission housing - must noticeably engage.
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Fig. 15: Clutch Actuator Pressure Line And Bolt
Courtesy of GENERAL MOTORS COMPANY

2. Install pressure line (1) and insert in fastening sleeve - must noticeably engage.
3. Attach pressure line and tighten nut (2).
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Fig. 16: Pressure Line And Retaining Clip
Courtesy of GENERAL MOTORS COMPANY

4. Attach connector for pressure line (1) and put connector on pressure line - retaining clip (2) must
noticeably engage.
5. Install the transmission. Refer to Transmission Replacement .

HYDRAULIC CLUTCH LOW PRESSURE HOSE REPLACEMENT

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Fig. 17: Hydraulic Clutch Low Pressure Hose
Courtesy of GENERAL MOTORS COMPANY

Hydraulic Clutch Low Pressure Hose Replacement

Callout Component Name
Preliminary Procedures

1. Reposition the expansion tank to the cooling system.

2. Bleed the clutch system so there is no fluid in the hose. Refer to Hydraulic Clutch System
Bleeding.
Hydraulic Clutch Low Pressure Hose

CAUTION:
Do not twist or damage the pipe assembly when removing the pipe assembly.

1
Procedure

1. Refill the brake fluid container and bleed the clutch. Refer to Hydraulic Clutch
System Bleeding.
2. Test the brakes and clutch after replacing the hose.

HYDRAULIC CLUTCH SYSTEM BLEEDING

WARNING: Refer to Brake Fluid Irritant Warning .

 CAUTION: Brake fluid must not come in contact with mineral oils and greases. The
smallest amount of such could lead to malfunction or breakdown of the
clutch.

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

NOTE: The hydraulic clutch actuation must only be bled from "below", i.e. from the
bleeder valve.

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Fig. 18: valve cap
Courtesy of GENERAL MOTORS COMPANY

NOTE: The following operational stages must be undertaken to fill the pressure
line between the master cylinder and the clutch actuator cylinder. When
bleeding, ensure that the brake fluid reservoir is always full and does not
run dry.
 1. Bleed pressure line between the clutch master cylinder and the clutch actuator cylinder using the
following procedure:
1. Remove the valve cap (3) from the bleeder valve.
2. Fill brake fluid reservoir up to "MAX" marking.
3. Press and hold clutch pedal.
4. Open bleeder valve until air or air/brake fluid mixture emerges.

NOTE: Do not close the bleeder valve too fast.

5. Close the bleeder valve.

6. Release the clutch pedal slowly.
7. Wait approximately 5 seconds.
8. Repeat this bleeding process 4 times.

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9. Tighten bleeder valve .
10. Push valve cap on to bleeder valve to protect the bleeder valve.
2. Check shifting for ease of movement with vehicle stationary, with engine running and with clutch
disengaged.
3. Road test the vehicle to ensure proper operation.

Undertake road test using varying RPM ranges and frequent gear changes, bring vehicle to operating
temperature during this process. Ensure the brake and clutch system is operating correctly.

CLUTCH PEDAL POSITION SENSOR REPLACEMENT

Removal Procedure
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Fig. 19: Clutch Pedal Position Sensor And Bolt
Courtesy of GENERAL MOTORS COMPANY

1. Disconnect clutch pedal position sensor wiring harness connector.

2. Remove clutch pedal position sensor bolt (2).
3. Remove clutch pedal position sensor (1).

Installation Procedure
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Fig. 20: Clutch Pedal Position Sensor And Bolt
Courtesy of GENERAL MOTORS COMPANY

1. Install clutch pedal position sensor (1).

CAUTION: Refer to Fastener Caution .

2. Install clutch pedal position sensor bolt (2) and tighten to 3 N.m (27 lb in).
3. Connect clutch pedal position sensor wiring harness connector.
4. Learn clutch pedal position sensor.

CLUTCH ASSEMBLY REPLACEMENT (WITH DT-6263)

Special Tools

 DT-6263 Remover and Installer

 DT-6263-25 Centering Drift
 DT-6263-30 Handle

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement .

NOTE: To prevent damage to the spring tangs of the thrust plate use DT-6263
remover and installer to remove and install the thrust plate.

Note the different lengths of the brackets for attaching DT-6263 remover
and installer to lower engine block. Thrust plate and clutch disc for
vehicles with self-adjusting clutch (SAC) are only available in Aftersales as
a set.

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Fig. 21: Clutch Assembly Remover And Installer
Courtesy of GENERAL MOTORS COMPANY

NOTE: DT-6263 remover and installer may only be attached to the engine block
and not to the oil pan, do not tighten bolts yet.

2. Attach DT-6263 remover and installer (1) to engine block.

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Fig. 22: Engine Block, Clutch Assembly Remover And Installer (DT-6263)
Courtesy of GENERAL MOTORS COMPANY

3. Attach DT-6263-30 handle (4) to centring drift (5).

CAUTION: Refer to Fastener Caution .

4. Fasten DT-6263 remover and installer.

1. Align DT-6263 remover and installer in center.
2. Insert centring drift with DT-6263-30 handle (2) through DT-6263 remover and installer into
clutch plate and crankshaft (center).
3. Tighten fastener (1).
4. Tighten fastener (3).
5. Tighten 4x fastener DT-6263 remover and installer on engine block.
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Fig. 23: Relieving Stress On Clutch Disc
Courtesy of GENERAL MOTORS COMPANY

5. Relieve stress on clutch disc.

1. Move DT-6263 remover and installer (1) so that it rests against spring tangs of the thrust plate.
2. Turn DT-6263 remover and installer clockwise to the stop.
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Fig. 24: Thrust Plate Fasteners
Courtesy of GENERAL MOTORS COMPANY

NOTE: Illustration 2156559 gives a better view of the clutch without DT-6263
remover and installer and centring drift with DT-6263-30 handle.

6. Remove thrust plate from flywheel. Remove 6 fasteners.

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Fig. 25: Attaching Thrust Plate
Courtesy of GENERAL MOTORS COMPANY

7. Detach thrust plate and clutch plate.

1. Turn DT-6263 remover and installer (1) anticlockwise to the stop.
2. Pull out centring drift with DT-6263-30 handle (2).
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Fig. 26: Inspect Clutch Plate For Excessive Wear
Courtesy of GENERAL MOTORS COMPANY

NOTE: Clutch plates contaminated by foreign bodies (oil, cleaning agent etc.)
must be replaced as a matter of principle. Check clutch disc for damage
and friction rust in the hub profile and replace if necessary. Do not clean
thrust plate and clutch disc with a high pressure cleaner or component
washing machine.

8. Check clutch plate for wear: Check the projection of the lining at the clutch lining rivets. The clutch plate
must be replaced if the lining projection is less than 0.5 mm. Also, press the clutch plate onto the
transmission input shaft and check for ease of movement.

Installation Procedure
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Fig. 27: Thrust Plate Fastener Locations
Courtesy of GENERAL MOTORS COMPANY

NOTE: Lettering "transmission side" faces the transmission.

 Do not tighten bolts yet.

 For a clearer representation, illustration 2156562 shows clutch
without centering drift with DT-6263-30 handle.

1. Attach clutch disc and thrust plate to flywheel.

Center thrust plate and clutch plate with centring drift and DT-6263-30 handle (1).
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Fig. 28: View Of Remover And Installer
Courtesy of GENERAL MOTORS COMPANY

NOTE: Tighten fastener crosswise.

2. Attach thrust plate to flywheel and turn DT-6263 remover and installer (1) clockwise to the stop.
 Tighten the trust plate - fastener M7 to 15 N.m (11 lb ft).

 Tighten the trust plate - fastener M8 to 22 N.m (16 lb ft).

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Fig. 29: Clutch Assembly Remover And Installer
Courtesy of GENERAL MOTORS COMPANY

3. Detach DT-6263 remover and installer (1) from engine block.

1. Turn DT-6263 remover and installer (3) anticlockwise to the stop.
2. Detach centring drift and DT-6263-30 handle (2).
3. Remove 4x fastener DT-6263 remover and installer on engine block.
4. Install the transmission. Refer to Transmission Replacement .

CLUTCH RELEASE BEARING REPLACEMENT

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement .

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Fig. 30: Clutch Release Bearing And Attached Components
Courtesy of GENERAL MOTORS COMPANY

2. Remove pressure line fastening sleeve (1).

 Unlatch fastening sleeve for pressure line on clutch housing (arrows).

 Draw fastening sleeve out of transmission slightly.

 Detach fastening sleeve for pressure line.

 Carefully unlatch 2x retaining lug (3).

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Fig. 31: Central Release With Hydraulic Line
Courtesy of GENERAL MOTORS COMPANY

3. Remove central release (1) with hydraulic line.

Remove 3x fasteners (arrow).

Installation Procedure
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Fig. 32: Central Release Location
Courtesy of GENERAL MOTORS COMPANY

1. Clean 3x thread (1) in transmission.

NOTE: Note installation position.

2. Install fastening sleeve for pressure line.

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Fig. 33: Central Release And Hydraulic Line Location
Courtesy of GENERAL MOTORS COMPANY

NOTE:  Use new bolts.

 It is essential to avoid pulling the central release at an angle.

3. Install central release (1) with hydraulic line.

 Clip hydraulic line in sleeve.

 Lightly coat seal ring in central release with transmission fluid.

 Preassemble 3 fasteners evenly in contact with the flange.

 Tighten the 3 fasteners from central release (arrow) to 6 N.m (53.1 lb in).

4. Install the transmission. Refer to Transmission Replacement .

CLUTCH ACTUATOR CYLINDER REPLACEMENT

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Fig. 34: Clutch Actuator Cylinder & Fasteners
Courtesy of GENERAL MOTORS COMPANY

Clutch Actuator Cylinder Replacement

Callout Component Name
Preliminary Procedures

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the transmission. Refer to Transmission Replacement .
3. Valid only for F40: Disconnect the clutch actuator cylinder pipe from the clutch actuator cylinder.
Refer to Clutch Actuator Cylinder Pipe Replacement.
Clutch Actuator Cylinder Fastener (Qty: 3)

CAUTION:
Refer to Fastener Caution .

1
Procedure
Use the appropriate thread sealant on the fasteners. Refer to Adhesives, Fluids,
Lubricants, and Sealers for the appropriate sealant.
Tighten
20 N.m (15 lb ft) plus 60 degrees

2 Clutch Actuator Cylinder

Procedure
 Bleed the clutch actuator cylinder after fitting the gearbox. Refer to Hydraulic Clutch
System Bleeding.

DESCRIPTION AND OPERATION

CLUTCH SYSTEM DESCRIPTION AND OPERATION

General

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Fig. 35: Pressure Plate
Courtesy of GENERAL MOTORS COMPANY

Power is transmitted from the flywheel on the engine to the input shaft in the gearbox via a driven plate. This
power is transmitted by the pressure plate, which is bolted to the flywheel, forcing the friction surface of the
driven plate against the flywheel.
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Fig. 36: Driven Plate
Courtesy of GENERAL MOTORS COMPANY

The driven plate is joined to the primary shaft with a splined joint. When the release bearing on the slave
cylinder presses on the "fingers" of the diaphragm spring, the fingers will act like levers to release the clamping
force of the pressure plate from the driven plate-flywheel. The engine is disengaged from the transmission in
this way.

Clutch with Dual-Mass Flywheel

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Fig. 37: Clutch Plate
Courtesy of GENERAL MOTORS COMPANY

The ability of modern, high-performance, low-weight engines to absorb vibrations themselves is poor. To
reduce noise and improve ride comfort, a dual-mass flywheel has been introduced on some models.

A dual-mass flywheel comprises two separate flywheel masses; a primary and a secondary mass with a spring
damper system connecting the two. This almost fully eliminates torsional vibrations in the gearbox and
transmission.

The primary section of the dual-mass flywheel is attached to the engine and the secondary mass on the
transmission side. These two masses are elastically attached with a spring assembly that absorbs torsional
vibrations from the engine.

Wide fluctuations of torque are above all produced during gear changes under load at lower engine speeds,
when driving at very low engine speeds when high torque is required and when the engine is started and
stopped. These torque peaks are absorbed by the arched springs. At high speeds, the springs are pressed out
against the spring housing, reducing their flexation. On the other hand, at how speeds, variations in torque are
small, reducing the significance of the outer springs.

Dual-mass flywheels do not have the springs that are normally fitted in the centre of the clutch plate, as the
flywheel itself has taken over their role.
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Fig. 38: Clutch with Dual-Mass Flywheel
Courtesy of GENERAL MOTORS COMPANY

The pressure plate is fully self-adjusting, which means that the compression springs acted on by the release
bearing are always in the same position relative to the release bearing. The diaphragm spring can move between
an adjustment ring and a wear ring.

When the clutch lining wears, the wear ring moves with the pressure surface of the pressure plate. This
movement reduces the load on the adjustment ring, which is rotated by two small springs and locked in position
by a catch in the pressure plate housing. This means that the diaphragm spring maintains its original position.

When replacing a dual-mass flywheel both the pressure plate and clutch plate centre should be changed as a
unit.

HYDRAULIC CLUTCH SYSTEM DESCRIPTION AND OPERATION

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Fig. 39: Master Cylinder And Connecting Pipes
Courtesy of GENERAL MOTORS COMPANY

Clutch operation is hydraulic and fully self-adjusting. The unit comprises:

 Master cylinder (1)

 Connecting pipes (2)
 Slave cylinder (3)

The master cylinder is mounted in the bulkhead and is connected to the clutch pedal via a piston rod.
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Fig. 40: Cylinder Housing And Split Piston
Courtesy of GENERAL MOTORS COMPANY

The slave cylinder is an integrated unit mounted in the clutch housing and comprises:

 Cylinder housing (4)

 Split piston (5)
 Fixed release bearing (6)

The slave cylinder cannot be disassembled. The hydraulic pressure from the master cylinder presses on the seal,
which then pushes the piston and release bearing against the pressure plate. A spring is mounted between the
cylinder housing and the release bearing, which means the release bearing, is always pressed against the
pressure plate and in this manner reduces the play in the clutch pedal.

A hydraulic line links the master cylinder and the slave cylinder damper pipe (to reduce pedal vibration) and has
a quick-release coupling at each end. The lower quick-release coupling, to the slave cylinder, has a bleed nipple.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

Tool
Illustration Number/Descrip

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DT-6174-A
MKM-6174-A
Connecting Hose
 DT-6263

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KM-6263
Remover/Install
 DT-50194

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Clutch Disc
Alignment Too