Clutch Assembly Replacement 3.6L Engine

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

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

2. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the transmission assembly. Refer to Transmission Replacement.



5. Mark the relationship of the pressure plate (3) to the flywheel (1) to maintain the correct balance condition on reassembly.
6. Loosen all pressure plate to flywheel retaining bolts (4) working from opposite sides to avoid distortion.
7. Continue loosening pressure plate to flywheel retaining bolts (4) from opposite sides until all are removed.
8. Remove the pressure plate (3) and clutch driven plate (2) from the flywheel (1).

Important: Do Not apply any lubricant to clutch driven plate splines if lubricant is applied premature failure could result.

Important: Install the clutch driven plate (2) with the short boss facing the flywheel (1). Flywheel side is stamped on the clutch driven plate hub (FW Side).

1. While holding the pressure plate (3), and clutch driven plate (2), together, align them to the flywheel (1).

Important: The pressure plate to flywheel retaining bolts (4) must not to be fully tightened at this stage.

2. Install the pressure plate to flywheel retaining bolts (4).

Do Not tighten at this stage.

3. Using a universal clutch driven plate centering tool (5) align the clutch driven plate (2) to the flywheel (1).

Notice: Refer to General Repair Instructions in the Preface section.

Notice: Refer to General Repair Instructions in the Preface section.

Notice: Refer to Fastener Notice in the Preface section.




4. Tighten the pressure plate to flywheel retaining bolts, using the sequence shown.
5. Tighten the flywheel.

Tighten
Tighten the bolts a first pass to 15 N·m (11 lb ft).

Tighten
Tighten the bolts a second pass to 30 N·m (22 lb ft).

6. Remove the clutch driven plate centering tool.

Notice: Refer to General Repair Instructions in the Preface section.

7. Install the transmission assembly. Refer to Transmission Replacement.
8. Inspect lubricant level in transmission, adjust as necessary. Refer to General Specifications.
9. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
10. Connect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
11. Enable the SIR. Refer to SIR Disabling and Enabling.
12. Road test vehicle for correct clutch operation.

Clutch Assembly Replacement 6.0L Engine

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.

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

2. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove transmission. Refer to Transmission Replacement.

Notice: Refer to General Repair Instructions in the Preface section.




5. Loosen all of the pressure plate to flywheel retaining bolts (4) working from opposite sides to avoid distortion.
6. Continue loosening pressure plate to flywheel retaining bolts (4) from opposite sides until all are removed.
7. Remove the pressure plate (3) and clutch driven plate (2) from the flywheel (1).

Notice: Refer to General Repair Instructions in the Preface section.

Notice: Refer to Clutch Pressure Plate Adjustment in the Preface section.





Important: Apply any a small amount of grease to clutch driven plate splines or transmission input shaft splines.

Important: Install the clutch driven plate (2) with the short boss facing the flywheel (1). Flywheel side is stamped on the clutch driven plate hub (FW Side).

1. While holding the pressure plate (3), and clutch driven plate (2), together, align them to the flywheel (1).

Important: The pressure plate to flywheel retaining bolts (4) must not to be tightened at this stage.

2. Install the pressure plate to flywheel retaining bolts (4).

Do not tighten at this stage.

3. Using a clutch driven plate centering tool (5) align the clutch driven plate (2) to the flywheel (1).
4. Install the pressure plate bolts (4), and insert the clutch centering tool (5).

Notice: Refer to Fastener Notice in the Preface section.




5. Tighten the pressure plate to flywheel retaining bolts, using the sequence shown.
6. Tighten the flywheel.

Tighten
Tighten the bolts a first pass to 15 N·m (11 lb ft).

Tighten
Tighten the bolts a second pass to 35 N·m (26 lb ft).

Tighten
Tighten the bolts a third pass to 55 N·m (41 lb ft).

Tighten
Tighten the bolts a fourth pass to 70 N·m (52 lb ft).

Notice: Refer to General Repair Instructions in the Preface section.

7. Install transmission. Refer to Transmission Replacement.
8. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
9. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.
10. Enable the SIR. Refer to SIR Disabling and Enabling in SIR.
11. Press the clutch pedal several times to allow the self-adjusting pressure plate function to take affect.
12. Road test vehicle for correct clutch operation.