Clutch: Service and Repair

Clutch Assembly Replacement

^ Tools Required
- J 5824-A Clutch Alignment Tool
- J 44747 Clutch Alignment Arbor

Removal Procedure





1. Remove the transmission.
2. Mark the flywheel and a lug on the clutch pressure plate for alignment purposes on installation.
3. If equipped with a 4.3L engine, remove the clutch pressure plate bolts (3), and washers (2).
4. Remove the clutch pressure plate (4) and disc (1).





5. If equipped with a 4.8L or 6.0L engine, remove the clutch pressure plate bolts.

Important: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel.

6. Remove the clutch pressure plate and disc from the dowel pins.





7. If equipped with a 6.6L or 8.1L engine, remove the clutch pressure plate bolts.

Important: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel.

8. Remove the clutch pressure plate and disc from the dowel pins.
9. If equipped with a NVG 4500 or a ZF S6-650 transmission, and ONLY the clutch disc is to be replaced, the pressure plate and NEW disc must be "reset" back to the "unworn" position.

Installation Procedure





1. If equipped with a 6.6L or 8.1L engine, install the clutch pressure plate and disc to the dowel pins.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install J 44747 in order to align the clutch.
3. Install the clutch pressure plate bolts.
^ Tighten the bolts to 70 Nm (52 ft. lbs.).

4. Remove the J 44747 .





5. If equipped with a 4.8L or 6.0L engine, install the clutch pressure plate and driven plate to the dowel pins.
6. Install J 5824-A in order to align the clutch.
7. Install the clutch pressure plate bolts finger tight.





8. If equipped with a 4.8L or 6.0L engine, tighten the clutch pressure plate bolts in the sequence shown.
^ Tighten the bolts to 70 Nm (52 ft. lbs.).

9. Remove the J 5824-A .





10. If equipped with a 4.3L engine, install the clutch disc (1), pressure plate (4), bolts (3), and washers (2).
11. Install J 5824-A in order to align the clutch.
12. Tighten the clutch pressure plate bolts.
^ Tighten the bolts to 40 Nm (30 ft. lbs.).

13. Remove the J 5824-A.
14. Install the manual transmission.