Clutch Kit Replacement Procedure for Chevrolet Cars

 

Clutch is one of the most crucial parts in the engine that acts as a connecting member between the engine and the transmission system in a car. Now replacing clutch on any car is a difficult and a tiring job if done by self.

The general clutch replacement procedure mainly depends upon the driveline setup of any car. This article talks about the clutch kit replacement on some Chevrolet car models.

Chevrolet Silverado

Chevrolet Silverado Clutch Kit Replacement is a bit complex compared to other front engine rear wheel drive cars because of its four wheel drive system configuration. 

  1. The first thing to be done while replacing the clutch is to raise the vehicle. It is advised to use a hydraulic lift when compared to conventional jack stands.
  2. After you have successfully raised the vehicle, disconnect the negative battery terminal.
  3. The next thing to do is drain out the fluids from the transmission and the transfer case. (Tip: You can also remove the front wheels to get some more space and light under the car)
  4. Disconnect the driveshaft connecting the transmission to the transfer case. The driveshaft is attached to the transmission through a U joint through six bolts and through four bolts at the transfer case end.
  5. The next thing to do is to remove the shift lever.
  6. Disconnect the electrical connections from the transmission. These include the speedometer cable, back up light sensor, four wheel drive sensor, and indicator light connection.
  7. Also disconnect the vent lines connecting the transmission to the transfer case.
  8. Disconnect the driveshaft connecting the transfer case and the rear differential. And then remove the transfer case after disconnecting the appropriate mounting bolts.
  9. Remove the cross member below the transmission.
  10. Disconnect the manual gear shifting lever from the driver’s cabin. The shifting lever is directly secured through bolts to the transmission.
  11. The next thing to do is to disconnect the slave cylinder, starter and the front dust cover.
  12. Remove all the bolts and mountings that secure the transmission after placing a suitable jack under it.
  13. Disconnect the hydraulic clutch lines and take care the fluid doesn’t contact the skin as it is highly corrosive. Also disconnect the fuel lines if required.
  14. Now gradually lower the transmission on the jacks, and get it out from under the car.
  15. Remove the bolts and remove the bell housing to get access to the clutch.
  16. Disconnect the release lever and the throw out bearing. 
  17. Remove the pressure plate and the clutch plate. Also remove the pilot bearing. (Tip : You can also go ahead and disconnect the flywheel if replacing it)

While replacing clutch use new pilot bearing if necessary. While installing a new clutch use a self centering tool to maintain alignment during installation. Apply suitable torque to the bolts as per the manufacturer’s catalog.

Attach all the parts back in their position and reconnect all the lines and cables back. Lower the car and fill all the fluids. 

Chevrolet Malibu

For those of you who own an old Chevrolet Malibu with a manual transmission, here’s the way to replace Chevrolet Malibu's Clutch Kit.

The car has a front engine rear wheel drive layout.

  1. Raise the vehicle on jack stands or a hydraulic lift is safer if used.
  2. Disconnect the negative cable of the battery and drain out fluids from the transmission and transfer case.
  3. Remove the driveshaft that connects the transmission to the differential. There are six bolts on the transmission side and four on the differential side.
  4. The next thing to do is to remove the shifting lever.
  5. Disconnecting the electrical connections from the transmission that include the speedometer cable, back up light sensor, four wheel drive sensor and indicator light connection.
  6. Remove the cross member from beneath the transmission.
  7. Remove the gear shift lever from the driver’s cabin that is secured to the transmission.
  8. Remove the front dust cover, slave cylinder and starter from their mounting.
  9. Remove all the bolts and mountings that secure the transmission after placing a suitable jack under it.
  10. Disconnect the hydraulic clutch lines and take care the fluid doesn’t contact the skin as it is highly corrosive. Also disconnect the fuel lines if required.
  11. Now gradually lower the transmission on the jacks, and get it out from under the car. Be careful not to damage it.
  12. Remove the bolts that secure the bell housing to get access to the clutch.
  13. Disconnect the release lever and the throw out bearing. 
  14. Remove the pressure plate and the clutch plate by undoing the bolts that secure it. After that you can get the pilot bearing out that can be sometimes difficult.

Replace the pilot bearing if necessary, clean and lubricate the throw out lever and bearing and other transmission parts before reinstalling. Use a self centering tool when attaching the clutch.

After the transmission and driveshaft are in their respective position redo all the connections and attach the gear shift lever. Lower the car and fill the fluids and reconnect the battery.

Chevrolet Cavalier


Replacing Clutch Kit on Chevrolet Cavalier can be a bit difficult considering the front engine front wheel drive layout. The system has the transmission, axles and the differential composing a single unit called ‘transaxle’. The transaxle is connected to the wheels through two half shaft connected through two constant velocity joints.

  1. Raise the vehicle up on jack stands or a hydraulic lift. Remove the front wheels.
  2. Lock the steering wheel in any direction by rotating it to stop the wheel disc assembly from moving.
  3. Open the hood and remove the air box and the hoses by undoing the screws and clamps that secure it.
  4. The next step is to disconnect and remove the battery from its tray and then remove the whole tray itself.
  5. Drain out the fluids from the transmission.
  6. Remove the slave cylinder and then remove the shift lever cable with a screwdriver. Also disconnect other cable connectors.
  7. Remove the starter by undoing the bolts that secure it.
  8. Disconnect the tie rod and stabilizer bar and disconnect the axle half shafts on both the sides with a pry bar. Repeat the same procedure on both the sides.
  9. Disconnect the connections of the transmission cooler with the transmission.
  10. Disconnect the throttle body from the engine and remove it along with the electrical connections attached to the throttle body.
  11. Remove the sub frame below the transmission.
  12. Carefully attach mounting braces to the engine. You can create more room by removing the radiator. Undo all the bolts that secure the transmission to engine or in other words remove the bolts that hold the bell housing.
  13. Remove all the engine mounts and suspend it on the mounting braces. Now carefully separate the transaxle from the engine using a suitable jack under it.
  14. Now you have the access to the clutch that can be removed by undoing the bolts that secure it. You can replace it with a new one.

After you a have installed a new clutch kit, it’s time to put all components in their respective position by following the above procedure in reverse order.

Chevrolet Impala

For those who own a Chevrolet impala with a front engine rear wheel drive, here’s how to replace the Clutch Kit in a Chevrolet Impala.

For those of you who own an old Chevrolet Malibu with a manual transmission, here’s the way to replace its clutch kit.

The car has a front engine rear wheel drive layout.

  1. Raise the vehicle on jack stands at a suitable height keeping in mind the size of the transmission.
  2. Disconnect the negative cable of the battery and drain out fluids from the transmission and transfer case.
  3. Remove the driveshaft that connects the transmission to the differential. There are six bolts on the transmission side and four on the differential side.
  4. The next thing to do is to remove the shifting lever.
  5. Disconnect the electrical connections from the transmission that include the speedometer cable, back up light sensor, four wheel drive sensor and indicator light connection.
  6. Remove the cross member from beneath the transmission.
  7. Remove the gear shift lever from the driver’s cabin that is secured to the transmission.
  8. The next thing to do is to remove the slave cylinder and starter from their mounting position.
  9. Remove all the bolts and mountings that secure the transmission after placing a suitable jack under it.
  10. Disconnect the hydraulic clutch lines and take care the fluid doesn’t contact the skin as it is highly corrosive. Also disconnect the fuel lines if required.
  11. Now gradually lower the transmission on the jacks, and get it out from under the car. Be careful not to damage it.
  12. Remove the bolts and remove the bell housing to get access to the clutch.
  13. Disconnect the release lever and the throw out bearing. 
  14. Remove the pressure plate and the clutch plate by undoing the bolts that secure it

Use a suitable jack to align the transmission and driveshaft in their respective position and then redo all the connections and attach the gear shift lever. Lower the car and fill the fluids and reconnect the battery.

While refitting the parts it has to be kept in mind that the assembly should be done with proper alignment using appropriate toque while fitting the bolts, or it may cause issues relating to all the parts during their running at high as well as low speeds.

Chevrolet Camaro

For all Camaro’s with a front engine rear wheel drive, here’s the procedure to replace the Chevrolet Camaro's Clutch Kit.

Chevy Camaro has a front engine rear wheel drive layout.

  1. Raise the vehicle on jack stands or a hydraulic lift is safer if used.
  2. Disconnect the negative cable of the battery and drain out fluids from the transmission and transfer case.
  3. Remove the driveshaft that connects the transmission to the differential. There are six bolts on the transmission side and four on the differential side.
  4. Disconnecting the electrical connections from the transmission that include the speedometer cable, back up light sensor, four wheel drive sensor and indicator light connection. And then go ahead and remove the shifting lever.
  5. Remove the cross member from beneath the transmission.
  6. Remove the gear shift lever from the driver’s cabin that is secured to the transmission.
  7. Remove the front dust cover, slave cylinder and starter from their mounting.
  8. Remove all the bolts and mountings that secure the transmission after placing a suitable jack under it.
  9. Disconnect the hydraulic clutch lines.
  10. Now gradually lower the transmission on the jacks, and get it out safely from under the car. 
  11. Disconnect the hydraulic clutch lines and take care the fluid doesn’t contact the skin as it is highly corrosive. Also disconnect the fuel lines if required.
  12. Undo the bolts and remove the bell housing to get access to the clutch.
  13. Disconnect the release lever and the throw out bearing. 
  14. Remove the pressure plate and the clutch plate by undoing the bolts that secure it. 
  15. Replace the pilot bearing if necessary, clean and lubricate the throw out lever and bearing and other transmission parts. And then it’s ready to go back. Use a self centering tool when attaching the clutch.

After the transmission and driveshaft are in their respective position, redo all the connections and attach the gear shift lever. Lower the car and fill the fluids and reconnect the battery.

 

 
 
  • http://www.highplainstransmission.com Clutch replacement

    Thank you for sharing this information. The information was very helpful and saved a lot of my time.

  • Magnaflow Mufflers

    Can the Clutch kit be used for Chevrolet Cars only. Can you inform me?