For 1990-2009 cars

## Clutch Pressure and Driven Plate Replacement 6-Speed

### Removal Procedure

1. Disconnect the battery negative cable. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   in General Information.
2. Remove the instrument panel driver knee bolster. Refer to Section 8C.
3. Remove the clutch master cylinder pushrod from the clutch pedal.
4. Raise the vehicle. Refer to Section 0A.

Notice: Do not allow the clutch actuator cylinder to hang by the hydraulic lines. This may damage the clutch hydraulic lines.

5. Remove the 6-Speed manual transmission. Refer to Transmission Removal in Manual Transmission.
6. Remove the flywheel housing cover bolts.
7. Remove the flywheel housing cover.
8. Remove the flywheel housing bolts.
9. Remove the flywheel housing.
10. Remove the pressure plate and cover bolts.
11. Remove the clutch pressure plate.
12. Remove the clutch pressure plate with the cover.
13. Remove the clutch driven plate.

### Inspect

1. Inspect the clutch pressure plate and the cover for wear or damage. Replace the components as necessary.
2. Inspect the clutch driven plate for wear or damage. Replace the clutch driven plate as necessary.
3. Inspect the engine flywheel. Replace the engine flywheel as necessary. Refer to Engine Flywheel Replacement in Engine Mechanical.

### Installation Procedure

#### Required Tools

J 38836 Clutch Alignment Arbor

1. Install the clutch driven plate to the engine flywheel.
2. Install the clutch pressure plate with the cover.
3. Install the pressure plate and cover bolts.

Tighten
Tighten the bolts finger tight.

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.

4. Use the J 38836 in order to align the clutch driven plate with the pilot bearing and the clutch pressure plate.

Tighten
Tighten the pressure plate cover bolts in a star pattern to 30 N·m (22 lb ft).

5. Install the flywheel housing.
6. Install the flywheel housing bolts.

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

7. Install the flywheel housing cover.
8. Install the flywheel housing cover bolts.

Tighten
Tighten the bolts to 8.5 N·m (75 lb in).

9. Install the 6-Speed manual transmission. Refer to Transmission Installation in Manual Transmission.
10. Lower the vehicle.
11. Install the clutch master cylinder pushrod to the clutch pedal.
12. Install the instrument panel driver knee bolster. Refer to Section 8C.
13. Connect the battery negative cable.

## Clutch Pressure and Driven Plate Replacement 5-Speed

#### Special Tools

• | J 33169 Clutch Alignment Arbor

• | J 36660-A Torque Angle Meter

### Removal Procedure

1. Remove the manual transmission. Refer to Transmission Removal .
2. Remove the clutch pressure plate bolts (1).
3. Remove the clutch pressure plate (2) and driven disc (4) from the dowel pins on the flywheel (3).

### Installation Procedure

Important: When the clutch driven plate requires replacement, the engine flywheel must also be replaced along with the clutch pressure plate as an assembly.

1. Install the clutch pressure plate (2) and driven plate (6) to the dowel pins on the flywheel (5).
2. Match the gray paint spot (7) on the pressure plate (2) to the X (4) on the flywheel (5).
3. Install the clutch pressure plate bolts (1) finger tight.
4. Install the J 33169 in order to align the clutch driven plate to the clutch pilot bearing.
5. Tighten the clutch pressure plate bolts (1).

Tighten
Tighten the clutch pressure plate bolts (1) to 20 N·m (15 lb ft). Use J 36660-A in order to tighten the bolts an additional 45 degrees.

6. Install the manual transmission. Refer to Transmission Removal .