Clutch Disc and Pressure Plate - Removal and Installation
You may find it is time, after many miles or extreme usage, to replace the clutch disc and pressure plate on your manual transmission car, truck, SUV or van. To do so, follow these instructions.
Note: this is a general description. Consult a repair manual or other reference material for the exact procedure.
Caution: The clutch disc may contain asbestos, a known cancer-causing agent. Never clean clutch surfaces with compressed air. Instead use a commercial brake-cleaning fluid. Never inhale any dust from clutch surfaces. Wear an approved air-filter mask when working on your clutch.
Use a hoist or floor jack to raise your vehicle at the front end. Secure with jack stands. Set the emergency brake and block the rear wheels.
Caution: always be extremely careful when raising and working under a raised vehicle.
Remove the transmission or transmission/transfer case assembly. Mark the flywheel and pressure plate so you can match them up again upon reassembly.
Loosen the pressure plate bolts, in rotation and a little at a time, to avoid warping the cover.
Remove the clutch disc and pressure plate.
Inspect the flywheel for cracks, scoring, warping, or other wear. Resurface or replace it if necessary. Note: Make sure the surface of the flywheel is clean before reinstalling the clutch.
Check the pilot bearing for damage or excessive wear. Replace if necessary.
Note: You will need a clutch alignment tool for installation for clutch disc and pressure plate installation.
If you have removed the pilot bearing, lubricate it lightly with grease before reinstalling. Using the clutch alignment tool, seat the bearing in the crankshaft.
Check clutch disc runnout. To do this, install the disc on the transmission input shaft. Measure runnout against the specs in your repair manual.
Install a clutch alignment tool in the pilot bearing. This will align the clutch assembly during installation.
Install the clutch disc on the alignment tool.
Install the pressure plate and hand-tighten the bolts. Note: You must tighten the pressure plate bolts a little at a time to avoid warping. Using an "X" pattern, torque down the bolts according to your repair manual specifications.
Re-install the transmission or transmission/transfer case assembly. Lower the vehicle.