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Bob
Bob, Auto Tech
Category: Chevy
Satisfied Customers: 4087
Experience:  Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
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The clutch, throughout bearing and fork..timing belt

Customer Question

I need step by step instructions to replace the clutch, throughout bearing and fork. And step by step for timing belt.
Submitted: 6 years ago.
Category: Chevy
Expert:  Bob replied 6 years ago.

Tools Required

J 28467-B (DW 117) Engine Support Fixture

Removal Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Install the J 28467-B .
  2. Remove the battery and battery tray.
  3. Remove the shift linkage assembly. .
  4. Remove the drive axle shaft.Object Number:(NNN) NNN-NNNN Size: SH

  5. Disconnect the backup lamp switch electrical connector.
  6. Disconnect the speedometer speed sensor electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH

  7. Remove the clutch release cylinder retaining bolts and the clutch release cylinder.
    Object Number:(NNN) NNN-NNNN Size: SH

  8. Remove the damping block connection nut and bolt.
  9. Remove the 3 rear mounting bracket bolts.
  10. Remove the rear mounting bracket from the transaxle.
    Object Number:(NNN) NNN-NNNN Size: SH

  11. Remove the 2 rear damping block retaining bolts.
  12. Remove the rear damping block from the front cross member.
    Object Number:(NNN) NNN-NNNN Size: SH

  13. Remove the 2 cage retaining bolts.
  14. Remove the 3 transaxle upper mounting bracket bolts.
  15. Remove the upper mounting bracket and cage.
    Object Number:(NNN) NNN-NNNN Size: SH

  16. Remove the 3 transaxle upper retaining bolts.
    Object Number:(NNN) NNN-NNNN Size: SH

  17. Support the transaxle with a transaxle support jack.
    Object Number:(NNN) NNN-NNNN Size: SH

  18. Remove the 7 transaxle lower retaining bolts.
    Object Number:(NNN) NNN-NNNN Size: SH

    Important: Rest the transaxle only in an upright position

  19. Remove the transaxle.
  20. Slide the transaxle sideways away from the engine block.
  21. Lower the transaxle.

Installation Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Support the transaxle with a transaxle support jack.
  2. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.
    Object Number:(NNN) NNN-NNNN Size: SH

  3. Install the 7 transaxle lower retaining bolts.

    Tighte

    Tighten the transaxle lower retaining bolts to 73 N·m (54 lb ft).
    Tighten the transaxle lower retaining bolt to 31 N·m (23 lb ft).
    Tighten the transaxle lower retaining bolt to 21 N·m (15 lb ft).

    Object Number:(NNN) NNN-NNNN Size: SH

  4. Install the three transaxle upper retaining bolts.

    Tighten
    Tighten the transaxle upper retaining bolts to 73 N·m (54 lb ft).


    Object Number:(NNN) NNN-NNNN Size: SH

  5. Install the cage retaining bolt and cage.
  6. Install the three transaxle upper mounting bracket bolts and bracket.

    Tighten
    Tighten the transaxle upper mounting bracket bolts to 60 N·m (44 lb ft).


    Object Number:(NNN) NNN-NNNN Size: SH

  7. Install the 2 rear damping block retaining bolts.

    Tighten
    Tighten the rear damping block retaining bolts to 55 N·m (41 lb ft).

  8. Install the rear damping block from the front cross member.
    Object Number:(NNN) NNN-NNNN Size: SH

  9. Install the 3 rear mounting bracket bolts and the bracket.

    Tighten
    Tighten the rear mounting bracket bolts to 80 N·m (59 lb ft).

  10. Install the damping block connection nut and bolt.

    Tighten
    Tighten the damping block connection nut and bolt to 80 N·m (59 lb ft).


    Object Number:(NNN) NNN-NNNN Size: SH

  11. Install the clutch release cylinder retaining bolts and the clutch release cylinder.

    Tighten
    Tighten the clutch release cylinder retaining bolts to 20 N·m (15 lb ft).


    Object Number:(NNN) NNN-NNNN Size: SH

  12. Connect the speedometer speed sensor electrical connector.
  13. Connect the backup lamp switch electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH

  14. Remove the J 28467-B .
  15. Install the drive axle shaft.
  16. Install the shift linkage assembly. .
  17. Install the battery and battery tray.
  18. Inspect the fluid level. .

Clutch and Pressure Plate Replacement

Tools Required

DT 46551 (DW210-010) Clutch Center Guide (alignment tool0

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Disconnect the negative battery cable.
  2. Remove the transaxle from the vehicle.
  3. Remove the pressure plate bolts and the pressure plate.
    Object Number:(NNN) NNN-NNNN Size: SH

  4. Important: Support the pressure plate when you remove the last bolt.

  5. Remove the clutch disc from the flywheel

Inspection Procedure


Object Number:(NNN) NNN-NNNN Size: SH

 

Visual Inspection of Clutch Disc

  1. Inspect the worn or oily contamination on the clutch surface.
  2. Inspect the damaged or weakened torsion spring.
  3. Inspect for a warped or bent clutch disc. After inspection, replace the new clutch disc, if necessary.

Clutch Disc Inspection

  1. Measure the rivet head depth from the clutch disc surface.
  2. Replace the clutch disc if the measured value is below the limit.

    Specification
    The rivet head depth standard is 1.2 mm (0.047 in), limit is 0.5 mm (0.020 in).


Object Number:(NNN) NNN-NNNN Size: SH

Clutch Disc Runout in Rotational Direction Inspection

  1. Measure runout using the dial gage.
  2. If runout exceeds the limit, replace the clutch disc.

    Specification
    The disc runout limit in rotational direction - periphery - is 0.7 mm (0.028 in).


Object Number:(NNN) NNN-NNNN Size: SH

Visual Inspection of the Pressure Plate

  1. Inspect for a worn diaphragm spring finger.
  2. Inspect for a worn or cracked pressure plate surface.
  3. Inspect for the polluted face by the oil. After inspection, replace the pressure plate if necessary.

Installation Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Coat the spline on the clutch disc with multi-purpose grease.
  2. Align the pressure plate and the clutch disc onto the flywheel using DT 46551 .
  3. Install the pressure plate bolts.

    Tighten

    For the hydraulic clutch type, tighten the bolts to 15 N·m (11 lb ft).
    For the cable clutch type, tighten the bolts to 18 N·m (13 lb ft).

  4. Remove DT 46551 from the clutch assembly.
  5. Install the transaxle into the vehicle.
  6. Connect the negative battery cable.

Release Bearing Replacement

Tools Required

DT 47513 (DW210-030) Bushing Joint Pipe
DT 47514 (DW210-040) Bushing Remover/Installer
J 2619-01 (09930-30102) Sliding Shaft
09943-88211 Bushing, Bearing Installer

Removal Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Remove the transaxle from the vehicle. .
  2. Remove the release arm (2). .
    Object Number:(NNN) NNN-NNNN Size: SH

  3. Remove the release bearing.
    Object Number:(NNN) NNN-NNNN Size: SH

  4. Remove the release shaft and bushing.
  5. Remove the No. 2 bushing and the seal using DT 47514 (1) and a hammer.
  6. Remove the release shaft (2).
    Object Number:(NNN) NNN-NNNN Size: SH

  7. Thread the tap (M16 x 1.51) (2) into the bushing.
    Object Number:(NNN) NNN-NNNN Size: SH

  8. Connect J 2619-01 (2) to the end of DT 47513 (1).
  9. Remove the bushing by pulling.

Release Bearing and Shaft Inspection

Bearing Inspection

Perform the following release bearing inspection:


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Inspect for noisy, worn and damaged release bearing.
  2. Inspect for a grabbing rotation of release bearing.
  3. Replace the release bearing if necessary.

Shaft Inspection

Perform the following release bearing shaft inspection


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Inspect for a warped shaft (1).
  2. Inspect for a worn fork (2).
  3. Replace the shaft if necessary.

Installation Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Install the release shaft No. 1 bushing using DT 47513 (2),09943-88211 (1) and a hammer.
    Object Number:(NNN) NNN-NNNN Size: SH

  2. Install the release shaft.
  3. Coat the release shaft and bushing with grease.
  4. Install the release shaft No. 2 bushing and seal using DT 47514 (1) and a hammer.
    Object Number:(NNN) NNN-NNNN Size: SH

  5. Coat the spline of transaxle input shaft with multipurpose grease.
  6. Coat the release bearing bore and the connecting of release shaft multi-purpose grease.
  7. Install the release bearing.
    Object Number:(NNN) NNN-NNNN Size: SH

  8. Install the release arm (2).
  9. Install the transaxle to the vehicle. .

Clutch Release Arm Replacement

Removal Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Mark the clutch release arm location to the release shaft position.
  2. Remove the adjusting nut (1) for the clutch cable.
  3. Remove the clutch control cable (2) from the release arm.
    Object Number:(NNN) NNN-NNNN Size: SH

  4. Remove the clutch release am retaining bolt and nut (1).
  5. Remove the release arm (2).

Installation Procedure
Object Number:(NNN) NNN-NNNN Size: SH

  1. Install the release arm to release shaft and align to the marked position (1).

    Tighten
    Tighten the release arm bolt and nut to 16 N·m (12 lb ft).

  2. Install the clutch control cable to the release arm and install the clutch control cable adjusting nut.
  3. Adjust the clutch cable.

Timing Belt Replacement

Tools Required

J 42492-A (KM-421-A) Timing Belt Adjuster
J 45059 Angle Meter
KM-470-B Angular Torque Gage

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Disconnect the air intake tube from the throttle body.
  4. Disconnect the breather tube from the valve cover.
    Object Number:(NNN) NNN-NNNN Size: SH

  5. Remove the air filter housing bolts.
  6. Remove the air filter housing.
  7. Remove the right front wheel. .
  8. Remove the right front splash shield.
    Object Number:(NNN) NNN-NNNN Size: SH

  9. Remove the accessory drive belt.
  10. Remove the crankshaft pulley bolt.
  11. Remove the crankshaft pulley.
    Object Number:(NNN) NNN-NNNN Size: SH

  12. Remove the upper front timing belt cover bolts.
  13. Remove the upper front timing belt cover by prying on the two tabs located on each side of the cover.
  14. Remove the lower front timing belt cover bolts.
  15. Remove the lower front timing belt cover.
  16. Remove the power steering pump mounting bolts, if equipped.
  17. Install the crankshaft pulley bolt.
    Object Number:(NNN) NNN-NNNN Size: SH

  18. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the timing mark at the bottom of the rear timing belt cover.
    Object Number:(NNN) NNN-NNNN Size: SH

  19. Slightly loosen the coolant pump retaining bolts.
  20. Using the J 42492-A (1), rotate the coolant pump counterclockwise to release the tension on the timing belt.
    Object Number:(NNN) NNN-NNNN Size: SH

    Important: Remove the timing belt behind the power steering pump.

  21. Remove the timing belt.

Installation Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  1. Align the timing mark on the crankshaft gear to the timing mark on the bottom of the rear timing belt cover.
    Object Number:(NNN) NNN-NNNN Size: SH

    Important: Ensure that the exhaust camshaft gear dowel pin is approximately in the 11 o'clock position.

  2. Align the timing marks on the camshaft gears.
  3. Install the timing belt.
    Object Number:(NNN) NNN-NNNN Size: SH

  4. Rotate the coolant pump clockwise using the J 42492-A (1).
    Object Number:(NNN) NNN-NNNN Size: SH

  5. Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned to the notch in the timing belt automatic tensioner bracket.
    Object Number:(NNN) NNN-NNNN Size: SH

  6. Tighten the coolant pump retaining bolts.
  7. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt.
  8. Loosen the coolant pump retaining bolts.
  9. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.
    Object Number:(NNN) NNN-NNNN Size: SH

  10. Tighten the coolant pump retaining bolts.

    Tighten
    Tighten the coolant pump retaining bolts to 10 N·m (89 lb in).


    Object Number:(NNN) NNN-NNNN Size: SH

  11. Remove the crankshaft pulley bolt.
  12. Install the upper and lower front timing belt cover.
  13. Install the upper and lower front timing belt cover bolts.

    Tighten
    Tighten the upper and lower front timing belt cover bolts to 10 N·m (89 lb in).


    Object Number:(NNN) NNN-NNNN Size: SH

  14. Install the crankshaft pulley.
  15. Install the crankshaft pulley bolt.

    Tighten
    Tighten the crankshaft pulley bolt to 95 N·m (70 lb ft) using a torque wrench. Using the J 45059 or the KM-470-B , tighten the crankshaft pulley bolt 30 degrees plus 15 degrees.

  16. Install the accessory drive belt, if equipped.
  17. Install the right front splash shield.
  18. Install the right front wheel. .
    Object Number:(NNN) NNN-NNNN Size: SH
  19. Install the air filter housing.
  20. Install the air filter housing bolts.

    Tighten
    Tighten the air filter housing bolts to 8 N·m (71 lb in).

  21. Connect the air intake tube to the throttle body.
  22. Connect the breather tube to the throttle body.
  23. Connect the IAT sensor connector.
  24. Connect the negative battery cable.
Bob, Auto Tech
Category: Chevy
Satisfied Customers: 4087
Experience: Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
Bob and 9 other Chevy Specialists are ready to help you
Customer: replied 6 years ago.
If I accept will I be able to view the required tools. Right now it does not lett me
Customer: replied 6 years ago.
I just accepted but I still can't view the required tools. Please e-mail me photes of them.
Your info was very helpfull.
Thank you
Expert:  Bob replied 6 years ago.

Sorry that is a major problem as this site will not let me post them as they are not formated correctly for the site to post. I will try to see if I can maybe scan copies and sent the pertinent ones. Actually they are pretty standard tools, Just an angle meter, and angle torque meter, a regular engine support and a clutch alignment tool. Will try to get something up for you and will let you know either way later today. Thanks for the accept.

Expert:  Bob replied 6 years ago.

This may take more than one post as there are 9 tools that I need to send to you. Some of them can be rented from most parts stores. The others you may have to buy. Be sure to scan left and right also. 3 tools this post. Sorry, can't change size. Good luck and thanks

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Expert:  Bob replied 6 years ago.

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Expert:  Bob replied 6 years ago.
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Customer: replied 6 years ago.
Bob, thanks so much for the tool pictures, it is a great help. Thanks again Mel
Expert:  Bob replied 6 years ago.
You are most welcome. My pleasure and happy we could help. Thanks for using JA.

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