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michael, ASE Certified Technician
Category: Pontiac
Satisfied Customers: 667
Experience:  ASE Master Tech, L1 Adv. Driveability Diag., ASE Alternative Fuel, over 18 years GM exp.
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How do I replace the clutch in a 2002 pontiac sunfire

Resolved Question:

how do I replace the clutch in a 2002 pontiac sunfire
Submitted: 8 years ago.
Category: Pontiac
Expert:  michael replied 8 years ago.
hello... do you know which model engine you have? is it a 2.2 or a 2.4? or if you could supply me with the 8th digit of the VIN would be a great help... so that i may get you the proper procedure.
Customer: replied 8 years ago.

Hi Michael

It's a 2.2

Expert:  michael replied 8 years ago.

hello... there are 2 "procedures"... the first details removal of the transmission... the other details replacement of the clutch and pressure plate...


Removal Procedure

  1. Disconnect the negative and positive battery cable ends from the battery.
  2. Remove the retaining bolt and the battery.
  3. Remove the washer solvent container.
  4. Install the engine support fixture. Refer to the instruction manual provided with the tool.
  5. Raise the engine enough to take pressure off of the transaxle mounts.
  6. Remove the air cleaner and duct assembly from the throttle body.
  7. Drain the cooling system.
  8. Remove the upper radiator hose.
  9. Remove the wire harness from the upper transaxle mount bracket.
  10. Remove the upper transaxle mount bolts.

  1. Remove the negative battery cable from the transaxle housing.
  2. Remove the starter.

  1. Disconnect the pressure line from the clutch actuator cylinder.

  1. Disconnect the backup light switch connector.

  1. Remove the rear transaxle mount bolts.

  1. Disconnect the vehicle speed sensor (VSS) .

  1. Remove the upper transaxle mounting bolts.

  1. Disconnect the shift cables at the transmission shift control and the bracket.

  1. Remove the cable bracket bolt and the bracket.

  1. Remove the rack and pinion mounting bolts.
  2. Raise and support the vehicle. Refer to Vehicle Lifting.
  3. Remove the tire and wheel assemblies.
  4. Remove the front fencer liners.
  5. Remove the front suspension crossmember. Leave the steering rack in the vehicle.
  6. Remove the flywheel support arm bracket from the flywheel cover to engine lower mount.
  7. Remove the flywheel housing cover bolts.
  8. Remove the flywheel housing cover.
  9. Remove the drive axles from the transmission. Secure the drive axles out of the way.

  1. Remove the engine strut from the bracket.
  2. Remove the front lower transaxle mount through-bolt.

  1. Attach the transaxle case to the support stand.

  1. Support the engine with a suitable axle jack.

  1. Remove the transaxle-to-engine mount bolts.
  2. Use the following procedure in order to remove the transmission:

34.1.Slide the transaxle away from the engine.
34.2.Carefully lower the bans axle jack.
34.3.Remove the transaxle.

Installation Procedure

  1. Install the transaxle to the engine block. Notice: Refer to Fastener Notice in Service Precautions.
  2. Install the transaxle-to engine lower mounting bolts.
    • Tighten the transaxle-to-engine lower mounting bolts to 75 Nm (55 ft. lbs.) .

  1. Remove the following components
    • The safety strap
    • The transaxle jack
  1. Install the front transaxle mount-through bolt.
    • Tighten the front transaxle mount-through bolt to 60 Nm (44 ft. lbs.) .

  1. Install the flywheel inspection cover.
  2. Install the washer solvent container.
  3. Remove the jackstand supporting the engine.
  4. Install the front fender liners.
  5. Install the drive axles.
  6. Install the front suspension crossmember.

  1. Install the engine strut-to-strut bracket.

  1. Install the rack and pinion mounting bolts.
    • Tighten the rack and pinion mounting bolts to 120 Nm (89 ft. lbs.) .
  1. Install the tire and wheel assemblies.
  2. Install the starter.
  3. Lower the vehicle.

  1. Install the upper transaxle mounting bolts
    • Tighten the upper transaxle mounting bolts to 96 Nm (71 ft. lbs.) .

  1. Connect the clutch master cylinder line.

  1. Connect the vehicle speed sensor.

  1. Connect the backup light switch.
  2. Remove the engine support fixture.

  1. Install the negative battery cable to the engine block.
  2. Install the upper radiator hose.
  3. Install the air cleaner assembly.
  4. Refill the cooling system.
  5. Fill the transaxle with Dexron III Transaxle Fluid GM P/N 12346143 (Canadian P/N 10952622) or equivalent.
  6. Bleed the clutch hydraulic system.
  7. Install the battery.




Removal Procedure

  1. Remove the transmission.
  2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved.

  1. Remove the clutch cover and the clutch disc.

Installation Procedure

  1. Align the Heavy Side of the flywheel assembly (stamped with an X), with the clutch cover Light Side (marked with paint).

  1. Install the J 29074 in order to support the clutch cover to the flywheel assembly.

Notice: Refer to Fastener Notice in Service Precautions.

  1. Install the clutch cover to flywheel bolts.

3.1.Follow the tightening sequence. Tighten the bolts to 20 Nm (16 ft. lbs.) . Rotate 45 degrees .
3.2.Tighten the bolts to specifications.

  1. Remove the J 29074.
  2. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent.
  3. Install the transmission.
  4. Bleed the hydraulic system.
  5. Connect the negative battery cable
michael and 4 other Pontiac Specialists are ready to help you
Expert:  michael replied 8 years ago.

hello... that procedure should cover it for you and installation is pretty straight forward from there.

michael and 4 other Pontiac Specialists are ready to help you