Chevrolet 2001 Corvette User manual

2000-01 CLUTCHES
Corvette
APPLICATION
MANUAL TRANSMISSION APPLICATIONS
DESCRIPTION & OPERATION
Systemusesa single-plate clutch disc, a diaphragmspring pressure plate and a permanently
lubricated clutch release bearing. Clutch release system is hydraulic. Corvette uses a concentric
actuator/release bearing assembly located in the clutch housing. The hydraulic system provides
automatic clutch release adjustment.
BLEEDING
1. Clean cap. Remove reservoir cap and diaphragm. Fill reservoir and keep full throughout
procedure. Disconnect negative battery cable. Raise and support vehicle. Disconnect heated
Application Transmission Model (RPO Code)
Chevrolet Corvette Borg-Warner T56 6-Speed (MM6)
NOTE: Bleeding is necessary if system has been opened or if air has been
drawn into system due to low fluid level in reservoir.
CAUTION: When battery is disconnected, vehicle computer, memory
systems and remote keyless entry transmitters lose memory
data. Driveability problems may exist until computer systems
have completed a relearn cycle. Information transmitters (tire
pressure, door lock/unlock, seat position memory, etc.) if
equipped, may not operate until reprogrammed. See
COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION and appropriate POWER DOOR LOCKS &
REMOTE KEYLESS ENTRY SYSTEMS article in ACCESSORIES
& EQUIPMENT before disconnecting battery.
CAUTION: DO NOT use silicone, mineral or paraffin base oil in clutch
hydraulic system, or damage to rubber parts in cylinders may
occur.
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2000-01 CLUTCHES Corvette
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oxygen sensor connectors. Remove exhaust take
-
down pipe flange nuts. Remove exhaust
intermediate pipe-to-rear pipe bolts. Remove front exhaust hanger bolts from bracket.
Remove rear exhaust hanger bolts from intermediate pipes. Remove intermediate pipe
assembly.
2. Remove driveline tunnel closeout panel. Attach hose to bleed screw on actuator and
submerge other end in container of hydraulic fluid. Have an assistant depress clutch pedal
slowly and hold. Loosen bleeder on clutch actuator cylinder to purge air from system.
Tighten bleeder and release pedal. Repeat procedure until all air is completely purged and
no bubbles are visible. Fill reservoir. Install diaphragm and cap.
3. Install driveline tunnel closeout panel and exhaust intermediate pipe. Lower vehicle. Apply
parking brake and block drive wheels. Shift transmission into Neutral. Start engine and run
at idle. Release clutch pedal. Depress clutch pedal and hold for 9 seconds. Attempt to shift
transmission into Reverse. If gears grind, bleed system again.
ADJUSTMENTS
CLUTCH PEDAL FREE PLAY & PEDAL HEIGHT
CLUTCH PRESSURE PLATE (OFF-VEHICLE)
1. Place pressure plate (flat surface down) on a press. Compress pressure plate diaphragm
spring fingers until tension is released from stepped adjusting ring. Place 2 screwdrivers
against 2 of 3 stepped adjusting tension spring stops, just ahead of adjusting ring tension
springs.
2. Using screwdrivers, rotate stepped adjusting ring counterclockwise (compressing tension
springs) until adjusting ring steps are fully adjusted out, and then continue to hold in
position. Release press pressure from pressure plate diaphragm spring fingers. Release
adjusting ring tension spring stops. Remove pressure plate from press.
CLUTCH PRESSURE PLATE (ON-VEHICLE)
1. Raise and support vehicle. Remove flywheel inspection cover. Have assistant press clutch
pedal until tension is released from clutch pressure plate stepped adjusting ring. Continue to
hold pedal. Place 2 screwdrivers against 2 of 3 stepped adjusting tension spring stops, just
NOTE: Clutch pedal free play and pedal height are automatically adjusted.
No manual adjustment is required.
NOTE: The following procedure must be performed with aid of an
assistant.
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ahead of adjusting ring tension springs.
2. Using screwdrivers, rotate stepped adjusting ring counterclockwise (compressing tension
springs) until adjusting ring steps are fully adjusted out, and then continue to hold in
position. Have assistant release clutch pedal. Release adjusting ring tension spring stops.
Install flywheel inspection cover. Lower vehicle.
TROUBLE SHOOTING
REMOVAL & INSTALLATION
CLUTCH ACTUATOR
Removal
1. Disconnect negative battery cable. Remove left instrument panel lower insulator panel.
Using a flat-blade tool, carefully pry instrument panel courtesy lamp assembly from left
lower closeout panel. Remove push-on retaining nut from steering column bracket stud.
2. Disconnect left lower closeout panel twist-
rivets from instrument panel lower support beam.
Insert instrument panel courtesy lamp assembly up through closeout panel. Lower and
remove closeout panel. Remove clutch master cylinder rod retainer. Remove clutch master
cylinder rod from clutch pedal. Raise and support vehicle.
3. Disconnect actuator hose from hose retaining clip at rear of engine. Using Hydraulic Clutch
NOTE: For trouble shooting, see appropriate table in TROUBLE SHOOTING
article in GENERAL INFORMATION.
NOTE: Transmission removal and installation procedures are included in
CLUTCH ASSEMBLY .
CAUTION: When battery is disconnected, vehicle computer, memory
systems and remote keyless entry transmitters lose memory
data. Driveability problems may exist until computer systems
have completed a relearn cycle. Information transmitters (tire
pressure, door lock/unlock, seat position memory, etc.) if
equipped, may not work until reprogrammed. See COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION
and POWER DOOR LOCKS & REMOTE KEYLESS ENTRY
SYSTEMS article in ACCESSORIES & EQUIPMENT before
disconnecting battery.
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Separator (J
-
36221), depress White circular release ring on actuator hose while pulling
lightly on master cylinder hose. Remove actuator cylinder hose fromhose retaining clip.
Disconnect clutch actuator cylinder hose from clutch master cylinder hose. Protect both
hose coupling ends from dirt and damage.
4. Remove driveline support assembly and transmission from vehicle. See CLUTCH
ASSEMBLY . Remove clutch actuator cylinder mounting bolts and actuator cylinder from
driveline support assembly.
Installation
When installing clutch hydraulic hoses, position hoses away from other components to prevent
damage. To install, reverse removal procedure. Tighten all bolts and nuts to specification. See
TORQUE SPECIFICATIONS . Bleed hydraulic system. See BLEEDING .
CLUTCH ASSEMBLY
Removal
1. Disconnect negative battery cable. On convertible models, remove folding top storage
compartment lid extension panel. On all models, open console door. Pull up on rear of
traction/ride control switch to release retaining clips. If switch does not release from trim
plate, carefully insert screwdriver into recess at rear of switch and gently pull up on rear of
switch. Disconnect electrical connector from switch, and remove switch.
2. Using small flat-blade screwdriver, carefully remove console retaining nut covers. Remove
front and rear retaining nuts. Remove instrument panel accessory trim plate nuts. Lift rear of
console slightly and pull rearward to release front of console from under instrument panel
trim plate. Disconnect electrical accessory plug connector. Unscrew electrical accessory
plug retainer from housing, and remove housing from console.
3. Disconnect fuel door release switch connector. Remove fuel door release switch. Turn
NOTE: When reconnecting quick-
connect hydraulic hose fittings, pull back
on fittings to verify engagement. DO NOT rely on audible click or
visual verification. Also check clutch hydraulic hoses for twists or
kinks.
CAUTION: When tilting rear of driveline downward, observe clearances
between rear of engine and composite dash panel, and
between rear of transmission assembly and underbody. To
prevent vehicle damage, DO NOT allow engine to rest
unsupported against composite dash panel.
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console over. Using small flat
-
blade screwdriver, carefully release switch tabs. Remove
console from vehicle. See Fig. 1 . Pry up and remove shift lever knob button. Pry control
knob retainer out of slots and remove retainer. Unscrew shift lever knob.
Fig. 1: Removing Center Console
Courtesy of GENERAL MOTORS CORP.
4. Grasp sidesof shift control boot and apply light pressure inward (toward shift lever) to
release boot retaining tabs from instrument panel accessory trim plate. Release all boot
retaining tabs. Lift boot away fromtrimplate and remove boot. Apply parking brake and
shift transmission into 4th gear to provide clearance. Open lighter door and remove ashtray.
Pry gently at side edge of accessory trim plate grille with flat-blade screwdriver to release
tab. Remove grille.
5. Remove accessory trimplate retaining screws next to lighter, behind ashtray, and in grille
opening. Grasp sides of accessory trim plate near curve at base. Lift rear of trim plate to
clear driveline tunnel studs and pull trim plate rearward to release locking tabs. Disconnect
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electrical connector fromlighter. Remove trim plate. Remove shift control closeout cover
retaining nuts, and remove cover. Shift transmission into Neutral.
6. Press down to engage shift control neutral lock pin. Remove transmission shift rod clamp
bolt. Remove shift control mounting bolts. Raise shift control assembly to release locator
fromshifter bracket on side of driveline support assembly. Release shift control from
transmission shift rod and remove shift control assembly. See Fig. 2 .
Fig. 2: Removing Shift Control Assembly
Courtesy of GENERAL MOTORS CORP.
7. Using a flat-blade screwdriver, carefully pry out courtesy lamp assembly from left lower
instrument panel closeout panel. Remove push-on retaining nut fromsteering column
bracket stud. Release lower closeout panel push-in retainers from instrument panel support
beam. Insert courtesy lamp assembly up through opening in closeout panel. Lower and
remove panel by releasing notch in right front edge of panel fromtab on accelerator pedal
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bracket.
8. Remove clutch master cylinder push rod retainer. Disconnect push rod fromclutch pedal.
Raise and support vehicle. Remove clutch actuator hose from retaining clip at rear of
engine. Using Hydraulic Clutch Separator (J-36221), depress White circular release ring on
actuator hose while pulling lightly on master cylinder hose to disconnect. Plug hose
openings. Remove rear wheels.
9. Disconnect oxygen sensor electrical connectors. Remove take-down pipe flange nuts.
Remove intermediate exhaust pipe-to-rear pipe bolts. Remove front exhaust hanger bolts at
take-down pipe bracket. Remove rear exhaust hanger bolts from rear intermediate pipes.
Remove intermediate pipe assembly. Wire muffler assemblies to underbody to support out
of way.
10. Remove driveline tunnel closeout panel bolts, and remove closeout panel. Measure rear
transverse spring stud height. See Fig. 3 . Carefully install Transverse Spring Compressor
and Adapters (J-33432-A and J-33432-97), and compress spring. DO NOT scratch or
damage transverse spring. Spring must be replaced if scratch is significant. Remove
retainers, nuts, bolts and insulators attaching transverse spring to lower control arms.
Remove mounting bolts, spacers and insulators attaching spring to crossmember. Remove
spring from vehicle.
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Fig. 3: Measuring Rear Transverse Spring Stud Height
Courtesy of GENERAL MOTORS CORP.
11. Support lower control arm with jack. Loosen, but do not remove, left outer tie rod end stud
nut. Install Ball Joint Separator (J-
42188) between suspension knuckle and tie rod end stud.
Tighten separator bolt until stud separates from knuckle. Remove separator and stud nut,
and separate tie rod end fromknuckle. Remove left lower shock absorber mounting bolt.
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12. Disconnect lower ball joint from steering knuckle. Loosen, but do not remove, left lower
ball joint stud nut. Install Ball Joint Separator (J-42188) between suspension knuckle and
ball joint stud. Tighten separator bolt until stud separates from knuckle. Remove separator
and stud nut, and separate ball joint from knuckle.
13. Repeat steps 11 and 12 for right side of vehicle. Install Transmission Support Fixture (J-
42055) on transmission jack. Position jack and firmly secure jack to transmission.
Disconnect wiring harness and brake hose clips from rear crossmember. Remove lower
differential-to-transmission nut. Remove transmission mount-to-rear crossmember nuts.
Place a transmission jack under rear crossmember and secure crossmember to jack. Using
hand tools only, remove rear crossmember retaining nuts.
14. With aid of an assistant, slowly lower rear crossmember and remove from vehicle. Remove
transmission mount bracket-to-differential bolts, and remove mount with bracket. Using pry
bar, gently release axle shafts from differential. Wire axle shafts to underbody. Remove
retainers holding wiring harness to driveline support and position out of way.
15.
Slowly lower driveline about 2" (50 mm), while adjusting angle of tilt to prevent damage to
body structure, until electrical connectors can be accessed. Disconnect vehicle speed sensor
electrical connector. Disconnect wiring harness retainer and clip from stud on top of
differential rear cover. Disconnect back-up light, reverse lockout solenoid, gear select (skip
shift) solenoid and transmission fluid temperature sensor electrical connectors from
transmission.
16. Insert putty knife between edge of shifter bracket on side of driveline support and brake
hose retainer on driveline tunnel wall. SLOWLY lower driveline while adjusting angle of
tilt, and check relationship between top rear of differential and lowest part of luggage
compartment floor. Differential should not be lowered past lowest point of luggage
compartment floor. PCV hoses, routed along rear of engine intake manifold, may contact
dash panel.
17. Release wiring harness retainer along top of transmission. Ensure harness is free of
driveline. Using a block of wood under rear of engine oil pan, place a jack under wood to
support engine and to keep engine fromresting on composite dash panel. Remove 5
CAUTION: Use an assistant to remove driveline and transmission
assembly to prevent damage to vehicle.
CAUTION: To prevent damage when tilting down, lowering and
removing rear of driveline, insert a putty knife or similar
tool between shift control bracket on driveline support
assembly and brake pipe retainer on driveline tunnel wall.
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driveline support
-
to
-
flywheel housing bolts. Carefully bend wiring harness bracket away
fromdriveline to allow clear path for driveline removal.
18. Have an assistant insert a flat-blade tool between edge of driveline support and engine
flywheel housing. Gently begin to pry driveline loose from engine. With an assistant guiding
front of driveline, slowly lower driveline, while watching angle of tilt and separating
driveline from engine, until drive shaft at front of driveline just clears flywheel housing.
Slowly lower driveline completely out of vehicle.
19. With driveline and transmission removed fromvehicle, clutch assembly can now be
serviced. Remove flywheel inspection cover bolts, and remove inspection cover. Remove
flywheel housing-to-engine bolts, and remove housing. Loosen pressure plate-to-flywheel
bolts alternately and evenly (one turn at a time) in a diagonal pattern until spring pressure is
released. Remove pressure plate and clutch disc. See Fig. 4 .
20. To continue transmission removal, position chain hoist around driveline assembly while
protecting exhaust hangers on driveline support. Raise transmission with hoist to remove
weight from transmission jack. Remove transmission support fixture from transmission jack
only. Place transmission/driveline assembly on workbench with hoist still attached. Ensure
adequate support is placed around assembly on workbench. Remove hoist from driveline.
21. Remove transmission-to-driveline bolts and studs. Using flat-blade screwdriver, pry
driveline support assembly away from transmission. Slowly slide driveline support assembly
away from transmission while guiding shift rod through opening in driveline support
assembly. Using a drift or punch, remove roll pin securing shift rod to shift shaft. Remove
shift rod. Remove differential-to-transmission bolts. Slowly separate differential from
transmission. If necessary, remove support fixture fromtransmission.
Inspection
1. Clean oil, grease, metal deposits, etc. fromflywheel mating surfaces. If flywheel or pressure
plate runout is greater than .050" (1.27 mm), flywheel and pressure plate must be replaced.
Inspect flywheel for cracks, heat marks, warpage or other damage. Slight surface scoring
can be removed with sandpaper. Replace or resurface as necessary.
2. Check pressure plate for warpage, heat marks (Blue in color) and cracks. Check diaphragm
spring fingers for uneven height and wear at throw-out bearing contact area. Replace
pressure plate if excessively worn or damaged. Replace clutch disc if runout is greater
than .020" (.51 mm). Check pilot bearing rotation. If roughness is felt or bearing does not
CAUTION:
Replace flywheel and pressure plate as a set if either has burn
damage, heat check damage, or runout exceeds specification.
Flywheel can be resurfaced only to clean up superficial
scoring.
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spin freely, replace bearing.
3. If replacing flywheel, check old flywheel for balance weights inserted in weight holes. If
weights are installed on old flywheel, new balance weights MUST be installed on new
flywheel in same hole locations as on old flywheel. If clutch pressure plate requires
replacement, flywheel MUST be replaced also.
Installation
1. Install flywheel, if removed. Apply Threadlock (12345382) to flywheel bolt threads.
Loosely install bolts. Tighten bolts in sequence in three steps. See Fig. 5 and TORQUE
SPECIFICATIONS
. Assemble clutch disc and pressure plate. Adjust clutch pressure plate.
See CLUTCH PRESSURE PLATE (OFF-VEHICLE) under ADJUSTMENTS. Install
clutch assembly to flywheel.
2. Using Clutch Alignment Arbor/Pilot Bushing Installer (J-38836), align clutch assembly to
pilot bearing. Tighten bolts in sequence. See Fig. 5
. Tighten bolts evenly over 3 increments.
See TORQUE SPECIFICATIONS . Install flywheel cover, inspection cover and cover
bolts.
3. Attach driveline to transmission assembly. Use an assistant to install driveline and
transmission in vehicle to keep tilt angle accurate to prevent damage to vehicle. Use only
hand tools to tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS .
4. To complete installation, reverse removal procedure. Ensure rear transverse spring stud bolt
has a MINIMUM of 2 threads showing above the nut. Set spring stud height to the height
measured during removal. See Fig. 3 . Adjust vehicle trim height. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Use NEW
crossmember mounting bolts. When reconnecting quick-connect hydraulic hose fittings, pull
back on fittings to verify engagement. DO NOT rely on audible click or visual verification.
Bleed hydraulic system. See BLEEDING .
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Fig. 4: Exploded View Of Clutch Assembly
Courtesy of GENERAL MOTORS CORP.
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Fig. 5: Flywheel Tightening Sequence (Pressure Plate Sequence Is Same)
Courtesy of GENERAL MOTORS CORP.
CLUTCH MASTER CYLINDER
Removal
1. Disconnect negative battery cable. Remove left instrument panel lower insulator panel.
Using a flat-blade tool, carefully pry instrument panel courtesy lamp assembly from left
lower closeout panel. Remove push-on retaining nut from steering column bracket stud.
2. Disconnect left lower closeout panel twist-
rivets from instrument panel lower support beam.
Insert instrument panel courtesy lamp assembly up through closeout panel. Lower and
remove closeout panel. Remove clutch master cylinder rod retainer. Remove clutch master
cylinder rod from clutch pedal. Disconnect windshield washer solvent level sensor electrical
connector, and remove washer solvent reservoir.
3. Raise and support vehicle. Remove clutch actuator cylinder hose fromhose retaining clip at
rear of engine. Using Hydraulic Clutch Separator (J-36221), depress White circular release
ring on actuator hose while pulling lightly on master cylinder hose. Disconnect clutch
actuator cylinder hose fromclutch master cylinder hose. Protect both hose coupling ends
fromdirt and damage.
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4. Lower vehicle, but leave on hoist. Remove clutch master cylinder push-in fasteners. Rotate
clutch master cylinder counterclockwise 45 degrees. Release cylinder from dash panel, and
remove clutch master cylinder and reservoir from vehicle.
Installation
To install, reverse removal procedure. DO NOT over-rotate master cylinder beyond 45 degrees.
Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS
. Bleed hydraulic
system. See BLEEDING .
CLUTCH PEDAL POSITION SWITCH
Removal & Installation
Disconnect negative battery cable. Remove clutch pedal position switch electrical connector.
Insert a feeler gauge between switch and clutch pedal bracket to release switch tab. Lift switch
slightly, then pull to remove. To install, reverse removal procedure. Insert switch locators into top
of slots, then slide down to lock.
HYDRAULIC HOSE
Removal
Remove clutch actuator cylinder or master cylinder. See CLUTCH ACTUATOR or CLUTCH
MASTER CYLINDER . Using a small drift or punch, remove roll-pin retaining hydraulic hose.
Drain off excess fluid from master cylinder into container.
Installation
To install, reverse removal procedure. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS
. Check NEW "O" ring for proper placement on hose. Rotate hose to ensure
NOTE: When reconnecting quick-
connect hydraulic hose fittings, pull back
on fittings to verify engagement. DO NOT rely on audible click or
visual verification. Also check clutch hydraulic hoses for twists or
kinks.
NOTE: When reconnecting quick-
connect hydraulic hose fittings, pull back
on fittings to verify engagement. DO NOT rely on audible click or
visual verification. Also check clutch hydraulic hoses for twists or
kinks.
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freedom of movement. Bleed hydraulic system. See
BLEEDING
.
PILOT BEARING
Removal & Installation
Remove driveline support assembly and transmission. See CLUTCH ASSEMBLY . Remove
pressure plate and clutch disc. Using Pilot Bearing Remover (J-23907), remove clutch pilot
bearing. Using Clutch Alignment Arbor/Pilot Bushing Installer (J-38836), install clutch pilot
bearing. To install, reverse removal procedure. Tighten all bolts and nuts to specification. See
TORQUE SPECIFICATIONS .
RELEASE BEARING
Removal
Remove driveline support assembly and transmission. See CLUTCH ASSEMBLY . Remove
clutch release bearing. Rotate bearing in either direction. Compression spring load will push
release bearing off end of clutch actuator cylinder.
Installation
DO NOT grease new clutch release bearing. New clutch release bearing is prelubed. Firmly push
clutch release bearing into place. Release bearing will snap over retainer tab. To install, reverse
removal procedure. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS .
OVERHAUL
HYDRAULIC COMPONENTS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
NOTE: DO NOT use grease under pressure to force pilot bearing from
crankshaft, or damage may result.
NOTE: Manufacturer recommends replacement of faulty clutch actuator
and master cylinders, and does not provide overhaul procedures.
Application Ft. Lbs. (N.m)
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Back-Up Light Switch 15 (20)
Differential-To-Transmission Bolt 37 (50)
Driveline Support Assembly-To-Engine Flywheel Housing Mounting
Bolt 37 (50)
Exhaust Hanger Bolt 37 (50)
Exhaust Take-Down Pipe Flange Nut 15 (20)
Flywheel Housing-To-Engine Bolt 37 (50)
Flywheel Inspection Cover Bolt 18 (25)
Flywheel-To-Crankshaft Bolt (1)
Step 1 15 (20)
Step 2 37 (50)
Step 3 74 (100)
Intermediate Exhaust Pipe Bolt 37 (50)
Lower Ball Joint Stud Nut
Step 1 15 (20)
Step 2
Additional 3 1/2
Flats
Step 3 Minimum41 (56)
Muffler Hanger Bolt 12 (16)
Outer Tie Rod End Stud Nut
Step 1 15 (20)
Step 2
Additional 160
Degrees
Step 3 33 (45)
Pressure Plate-To-Flywheel Bolt 47 (64)
Rear Crossmember Mounting Bolt/Nut (2) 81 (110)
Rear Drive Axle Spindle Nut 118 (160)
Reverse Lock-Out Solenoid Bolt 30 (41)
Shift Control Assembly Mounting Bolt 22 (30)
Shift Rod Clamp Bolt 22 (30)
Shock Absorber Mounting Bolt
Lower 162 (220)
Upper 22 (30)
Skip Shift (Gear Select) Solenoid Bolt 37 (50)
Tie Rod Jam Nut 44 (60)
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Transmission-To-Driveline Support Bolt 37 (50)
Transmission Mount-To-Rear Crossmember Bolt 37 (50)
Transverse Spring Mounting Bracket Bolt 46 (62)
Wheel Hub Mounting Bolt 96 (130)
INCH Lbs. (N.m)
Clutch Actuator Cylinder Bolt 106 (12)
Console Retaining Nut 89 (10)
Driveline Tunnel Closeout Panel Bolts 89 (10)
Instrument Panel Trim Plate Screw 27 (3)
Shift Control Closeout Cover Nut 106 (12)
(1) Apply Threadlock (12345382) to all bolts.
(2) Always use NEW bolts and nuts.
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2000-01 CLUTCHES Corvette
MY
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