Chevrolet Clutch Kit Installation Instructions

I. Preparation

Safety and Protection

• Disconnect the negative terminal of the battery to prevent short circuits. Park the vehicle on a level surface, engage the parking brake, place wheel chocks, and lift and lock the vehicle in place using a lift according to specifications.

• Wear safety goggles and gloves, and use professional tools to avoid personal injury or equipment damage caused by improper operation.

Tool List

• Lift/jack, socket wrench set, torque wrench (accuracy ±3%), clutch alignment tool (or transmission input shaft as a substitute), flywheel holding tool, puller (for release bearing), lubricating grease (high-temperature bearing grease), cleaning agent (residue-free).

Parts Inspection

• Confirm that the kit model matches the vehicle. Check the pressure plate flatness (using a straightedge + feeler gauge, gap ≤0.1mm), clutch disc thickness (new disc approx. 10mm, replace if worn to ≤7mm), and ensure the release bearing operates without jamming or abnormal noise.

II. Removing the Old Kit (Key Steps)

1. Remove the engine splash shield, halfshafts/drive shafts, shift mechanism, and auxiliary pipelines. After supporting the transmission, remove the bolts connecting it to the engine, then smoothly separate and lift the transmission.

2. Secure the flywheel with a holding tool, loosen the clutch cover bolts in stages diagonally, remove the old pressure plate and clutch disc. Take off the release bearing, pilot bearing, and fork assembly.

3. Clean the flywheel surface (remove oil stains, rust, and wear particles), check for end runout (≤0.1mm) and cracks. Replace if necessary.

III. Installing the New Kit (Core Process)

Basic Component Assembly

• Install the new pilot bearing and apply lubricating grease. Mount the release bearing, fork, and return spring, ensuring the dust cover is intact and properly seated.

• Apply high-temperature lubricating grease to the contact area between the release bearing and fork to prevent abnormal noise or premature wear from dry friction.

Clutch Disc and Pressure Plate Installation

• Install the clutch disc with the damper side facing the pressure plate. Use a clutch alignment tool to ensure coaxiality between the clutch disc and flywheel center, avoiding difficulty in installing the input shaft.

• Align the mating marks on the clutch cover and flywheel (mark positions during removal if no original marks exist). After the pressure plate fits the flywheel, tighten the bolts evenly in 2–3 stages diagonally to the specified torque (Cruze example: 25Nm). Never tighten in one step to prevent deflection and deformation.

• Install the release bearing dust cover, preload the retaining ring according to specifications (e.g., Cruze: A=18mm), and torque the locking bolt to 15Nm.

Transmission Reset

• Clean the transmission input shaft splines and apply a thin layer of lubricating grease. Align with the alignment tool and smoothly insert the transmission, then tighten the connecting bolts to the specified torque (refer to the vehicle manual).

• Reinstall the halfshafts/drive shafts, shift mechanism, and pipelines. Fill with transmission fluid of the correct specification to the standard level.

IV. Adjustment and Testing

Clutch Free Travel Adjustment

• Mechanical type: Adjust the position of the release fork shaft lever (e.g., Cruze: 195–205mm from the fixed cable nut bracket), ensuring a pedal free travel of 15–25mm.

• Hydraulic type: Check for no leakage in the master/slave cylinder. After bleeding air, adjust the free travel to vehicle specifications (usually 10–15mm) via the pedal push rod.

Functional Testing

• Start the engine and test the smoothness of gear shifting at idle, ensuring no jamming or abnormal noise. Depress the clutch lightly to verify a clear engagement point, no slipping (no abnormal RPM increase during sudden acceleration), and complete disengagement (no drag in neutral).

• Conduct a road test (low speed → high speed) to confirm smooth starting without vibration, smooth gear shifting, and no abnormal vibration or odors, with all data meeting vehicle technical requirements.

V. Key Technical Specifications (Cruze Reference)

Key Precautions for Chevrolet Clutch Kit Installation

I. Safety and Environment

• Park the vehicle on a level surface, engage the parking brake, and place wheel chocks. Disconnect the negative terminal of the battery, lift and lock the vehicle with a lift according to specifications to prevent falling.

• Wear safety goggles and oil-resistant gloves. Avoid cleaning the clutch friction surface with dry brushes or compressed air to prevent dust hazards.

• Store parts separately by category and mark mating positions during disassembly (if no original factory marks exist) to avoid incorrect installation.

II. Cleaning and Inspection

• Clean the flywheel end face (free of oil stains, rust, and wear particles). Check for end runout ≤0.1mm and no cracks; replace if necessary. Test the pressure plate flatness with a straightedge and feeler gauge, ensuring the gap ≤0.1mm.

• The clutch disc friction surface must be free of oil contamination. Apply a small amount of high-temperature lubricating grease to the spline hub (avoid excessive application to prevent friction surface contamination).

• Inspect the release bearing and pilot bearing for no jamming or abnormal noise. Ensure the hydraulic release bearing seal ring is intact to prevent leakage.

III. Positioning and Orientation

• Install the clutch disc with the damper side facing the pressure plate. Reversing the orientation will result in incomplete disengagement or inability to shift gears.

• Use a clutch alignment tool (or input shaft) to ensure coaxiality between the clutch disc, flywheel, and pressure plate; otherwise, the transmission input shaft will be difficult to install.

• Align the assembly marks on the clutch cover and flywheel, and ensure the locating pins are accurately seated to guarantee uniform force distribution.

References：

I. Original Factory Service Manuals (Core Basis)

Chevrolet Cruze Service Manual (SAIC-GM, Document No.: SI–10006) - Clutch Chapter

• Tighten the pressure plate bolts diagonally in 2–3 stages with a standard torque of 25Nm.

• Preload the release bearing retaining ring to A=18mm, with a locking torque of 15Nm.

• For mechanical clutches: The distance between the release fork shaft lever and the fixed cable nut bracket is 195–205mm, and the pedal free travel is 15–25mm.

• Mandatory requirements: Install the clutch disc with the damper side facing the pressure plate, and ensure coaxial installation with a centering tool.

Chevrolet Trax Original Factory Service Guide - Clutch Trio Replacement Specifications

• Geometric tolerance requirements: Flywheel end runout ≤0.1mm; pressure plate flatness ≤0.1mm.

• Lubrication specifications for the contact area between the release bearing and fork, as well as the input shaft splines.

II. National Standards (Industry Universal Basis)

Technical Conditions for Automobile Clutch Repair (GB/T 15742–2019)

• Clause 4.2: Flywheel end runout ≤0.1mm; pressure plate flatness ≤0.1mm; the clutch disc friction surface shall be free of oil stains, cracks, and exposed rivets.

• Clause 5.3: Tighten the pressure plate bolts evenly diagonally to avoid eccentric load and deformation.

• Clause 6.2: The release bearing shall operate without jamming or abnormal noise; the dust cover shall be intact, and lubrication shall comply with specifications.

• Clause 7.1: Test requirements for clutch pedal free travel, engagement point, and complete disengagement.

III. Industry Universal Specifications and Technical Documents

General Principles of Assembly Technology in the Automobile Maintenance Industry

• General requirements: Fasteners shall be tightened in stages according to torque specifications; mating marks of key components shall be aligned.

• Application specifications for high-temperature lubricating grease (e.g., molybdenum-based) on release bearings and pilot bearings.

General Motors Global Service and Parts Operations (GMSPO)

• Torque standards for connecting bolts between the transmission and engine; operational guidelines for applying a thin layer of lubricating grease to input shaft splines.

• Procedures for bleeding air from hydraulic clutches and requirements for leakage detection.

IV. Common Citation and Verification Methods