For 1990-2009 cars

#### Tool Required

• | J 34860 Clutch Alignment Arbor

• | J 26900-5 Vernier Caliper

• | J 36660-A Electronic Torque Angle Meter

• | J 35271 Flywheel Lock

### Removal Procedure

1. Remove the manual transaxle assembly from the vehicle. Refer to Transmission Replacement in Manual Transmission -MB4 and MB5.
2. Use the J 35271 in order to hold the flywheel before removing the bolts.
3. Slowly and evenly loosen the 6 clutch pressure plate cover bolts (2) until the clutch pressure plate spring tension is completely released.
4. Remove the 6 clutch pressure plate cover bolts and the pressure plate from the flywheel.
5. Remove the clutch disc from the flywheel.

Important: Index the flywheel (1) in relation to the crankshaft using a china marker before removal in order to verify correct installation. Poor engine and/or transaxle balance results if the flywheel is installed in a position other than the original position.

6. Remove the 8 flywheel bolts and the flywheel from the crankshaft. Note the flywheel position on the crankshaft.
7. Clean the flywheel (2) and the clutch pressure plate-to-clutch disc (1, 3) mating surfaces of the following substances:

• | Oil

• | Grease

• | Metallic particles

8. Clean the clutch disc (1) using a clean dry cloth.
9. Inspect the flywheel (2) and the clutch pressure plate (3) for the following conditions:

• | Cracks

• | Heat checking

• | Grooves

• | Excessive wear

• | Bent or broken pressure plate spring levers

• | Weak or damaged diaphragm spring

Notice: If any of the following conditions exist, do not attempt to disassemble or repair the clutch pressure plate. If the flywheel or the clutch pressure plate appears excessively worn, replace the flywheel and/or clutch pressure plate as necessary.

10. Inspect the clutch disc for the following conditions:

• | Cracks

• | Excessive wear

• | Damaged or weak torsional springs

11. Use J 26900-5 in order to measure the clutch disc (1) wear. Measure the depth of each rivet head depression (2). The following specifications are standard rivet head depth measurements:
12. Replace the clutch disc if the clutch rivet depth is less than 0.5 mm (0.02 in).

### Installation Procedure

1. Install the flywheel to the crankshaft. Align the flywheel-to-engine marks.

Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

2. Apply GM P/N 12345493, or the equivalent, to the flywheel retaining bolt threads (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.

3. Install the 8 flywheel retaining bolts to the crankshaft.

Tighten
Tighten the 8 flywheel retaining bolts in the specified sequence to 88 N·m (65 lb ft).

4. After the proper torque has been reached, use J 36660-A and retighten the flywheel bolts in the specified sequence an additional 90 degrees.
5. Install the clutch disc to the flywheel with the torsion springs offset toward the transaxle. Use the J 34860 in order to center and hold in place the clutch disc on the flywheel.
6. Install the clutch pressure plate to the flywheel. Secure the flywheel with the 6 clutch pressure plate cover bolts.

Tighten
Tighten the clutch pressure plate cover bolts to 23 N·m (17 lb ft).

7. Remove the J 34860 .
8. Lubricate the transaxle input shaft splines and clutch release bearing using a thin coat of wheel bearing grease GM P/N 1051344 (or equivalent).
9. Install the manual transaxle assembly into the vehicle. Refer to Transmission Replacement in Manual Transmission -MB4 and MB5.