How to Repair a Clutch

The clutch in your vehicle works by applying force against a flywheel mated to your engine using a clutch disc and pressure plate. The clutch is made of friction material and is designed to "grab" the flywheel as it turns. This translates into rotational force transferred to the wheels through the transmission. Over time, your clutch disc will wear down and begin to slip. When this happens, you will have trouble accelerating in any gear because the clutch will lose the ability to "grab" the flywheel. At this point, the clutch disc will need to be fixed. To do this, replace the entire clutch assembly.

Things You'll Need

• 2 Floor jacks with 2 jack stands
• Flat block of wood
• Catch pan
• Clutch alignment tool
• Socket wrench and socket set
• New clutch assembly
• Brake parts cleaner
• Torque wrench
• Safety glasses and mask
• Zip-ties
• Pliers
• Flat-tip screwdriver
• Air compressor and impact wrench

Instructions

Removal

1. Loosen the lug nuts on the front wheels by turning them 45 degrees with a tire wrench. Do not unseat the wheel from the hub.

2. Disconnect the cable running to the negative battery terminal. Loosen the nut on the cable clamp holding the cable to the negative battery terminal. Slide the clamp off the terminal.

3. Raise the vehicle onto jack stands using the jack. Jack up on the front jack point of your vehicle and place jack stands under the front pinch welds of the vehicle (normally located underneath the front doors on the frame). Then, lower the vehicle onto the stands.

4. Finish removing the lug nuts and pull the wheel off.

5. Remove the upper and lower caliper mounting bolts, slide the caliper off the rotor and secure it to the coil springs on the suspension.

6. Pull the rotor off the wheel hub.

7. Remove the cotter pin holding the drive axle nut in place.

8. Remove the drive axle nut with an impact wrench.

9. Loosen and remove the tie-rod end bolt.

10. Swing the steering knuckle and wheel hub out of the way while you remove the axle from the transaxle. Pry the end of the axle out of the transaxle with a flat-tip screwdriver. Be sure not to damage the rubber seal on the transaxle while you do this.

11. Support the transaxle with a floor jack. Support the engine with another, separate, floor jack. Make sure to use a flat block of wood when supporting the engine so that you spread out the force being applied by the jack on the engine.

12. Position the catch pan under the transaxle and remove the drain bolt on the transaxle and drain the transaxle fluid into the catch pan.

13. Disconnect the shift linkage from the transaxle.

14. Disconnect the clutch linkage from the transaxle.

15. Disconnect the speedometer and electrical cables from the transaxle.

16. Remove the bolts holding the exhaust piping to the manifold, unplug the electrical connectors running to the O2 sensors and slide the entire exhaust system off the hangers attached to the underbody of the vehicle. This will remove the exhaust system from the vehicle.

17. Remove the transaxle to engine bolts and the transaxle mounts.

18. Pull the transaxle away from the engine and lower it to the ground.

19. Support the clutch by sliding a clutch alignment tool into the center of the clutch while you remove the pressure plate to transaxle bolts.

20. Pull the clutch assembly off the transaxle, clean the surface of the new clutch, the flywheel and surrounding areas with brake parts cleaner. Install the new clutch. Installation is the reverse of removal.

Tips & Warnings

• Be sure to torque all bolts to the torque specifications listed in your vehicle's shop manual. Exact clutch removal details may vary according to vehicle; for specific information, consult the particular vehicle's manual (see Resources).

Resources

• Automobile Shop (service) Manuals