SECTION 7A1 - CLUTCH - GEN III V8 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air bags or seat belt pre-tensioners, driv er’s and front passenger’s air bag and left and righ t

hand side air bags. Refer to SAFETY PRECAUTIONS of the Service Information before performing any

service operation on, or around any SRS components, the steering mechanism or wiring. Failure to

follow the SAFETY PRECAUTIONS could result in SRS deployment, resulting in possible personal injury

or unnecessary SRS system repairs.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service

Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as

detailed in 4. DIAGNOSIS, ABS or ABS/ETC FUNCTION CHECK, in Section 12L ABS & ABS/ETC, (V6

Engine) or (GEN III V8 Engine) of this Service Information CD.

1. GENERAL INFORMATION

As the clutch and operating system for V6 engined vehicles remains unchanged since the start of VT Series

production, this Section will only detail the changes made to the clutc h and its operating s ystem as they apply to the

GEN III V8 engine when the manual transmission, production option MM6, is fitted.

For service operations relating to the clutch and operating system on V6 engined, VT Series vehicles, refer to

Section 7A CLUTCH of the VT Series I Service Information.

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2. GENERAL DESCRIPTI ON

2.1 SELF-ADJUSTING CLUTCH PRESSURE PLATE

GEN III V8 ENGINE

By adopting a s elf - adjus ting f eatur e f or the clutc h pres s ure plate f itted to the G EN III V8 engine, sever al advantages

are achieved:

a. The clutch pedal loading is maintained at a consistent level throughout the life of the assembly, as the

diaphragm spring leverage over the pivot rings remains the same.

b. This also results in the fa ct that the clutch ‘take- up’ remains at a constant point, with the clutch pedal feel also

remaining constant.

c. No maintenance adjustments are required.

1. Bearing - Clutch Pilot

2. Flywheel – Engine

3. Bolt - Flywheel (6 places)

4. Plate - Clutch Driven

5. Plate - Clutch Pressure

6. Bolt - Pressure Plate (6 places)

7. Assembly - Clutch Slave

8. Bolt - Slave Cylinder (2 places)

Figure 7A1-1 - Clutch Components

2.2 CLUTCH CONTROL

Hydraulic actuation for the clutch has been retained f or the GEN III V8 engine application and uses s ome com mon

components with the V6 engined vehicle. For example, apart from the changed orientation of the outlet fitting, the

clutch master cylinder remains unchanged.

The clutch pedal is also common, except for those vehicles fitted with cruise control, when a small bracket is welded

to the pedal for clutch switch control.

Clutch control component changes that are unique for the GEN III V8 engine are:

• Hydraulic piping from the flexible hose to the clutch slave cylinder, routed across the top of the manual

transmission.

• An integrated clutch throwout bearing and concentric slave cylinder, mounted to the front of the transmission

adaptor plate.

ARRANGEMENT

1. Bracket - Clutch Fluid Reservoir

2. Reservoir - Clutch Fluid

3. Hose - Reservoir to Master Cylinder

4. Master Cylinder

5. Pipe - Master Cylinder to Slave Cylinder

6. Hose - Master Cylinder Pipe to Slave Cylinder Pipe

7. Assembly - Slave Cylinder and Bearing

8. Pipe - Hose to Slave Cylinder

9. Pedal - Clutch

10. Bush - Master Cylinder Push Rod

11. Retainer - Push Rod Bush

12. Switch - Clutch (Cruise Control only)

Figure 7A1-2 Clutch Control Layout

OPERATION

Brak e fluid is f ed to the clutch m aster cylinder fr om

a remote reservoir mounted to a bracket, bolted to

the end of the brake m aster cylinder. A flexible line

connects the two components.

The master cylinder is attached to the firewall in the

engine compartment.

The clutch pedal is mounted in the clutch/brake

pedal support bracket, bolted to the dash panel.

The clutch master cylinder piston is connected to

the clutch pedal by an adjustable push rod, that is

bushed and retained by a spring clip.

No clutch adjustments are required. Although the

clutch master cylinder push rod does feature an

adjustment, it is only for production purposes and is

not to be tampered with, in service.

Stroking of the clutch throwout bearing is achieved

by using a concentr ic hydraulic clutch s lave cylinder

(2) mounted to the front of the transmission adaptor

plate housing.

Hydraulic connection to the master cylinder is by

steel piping from the master cylinder, flexible hose

to the transmission and steel pipe again from the

flexible hose to the slave cylinder (1) (Also see

Figure 7A1-2).

The slave cylinder is fitted with a bleed valve to

assist in removal of air from the hydraulic system.

Apart from the thr owout bearing ass em bly and load

spring, there are no other serviceable parts in the

slave cylinder and, if found to be faulty, the

assembly must be replaced.

NOTE: This actuation arrangem ent is unique to the

GEN III V8 engined vehicle. Figure 7A1-3

CLUTCH MASTER CYLINDER OPERATION

As the operation of the clutch mas ter cylinder fitted

to GEN III V8 engined vehicles is the same as for

all VT vehicles, refer to the description in

Section 7A CLUTCH, of the VT Series I Service

Information.

CLUTCH SLAVE CYLINDER OPERATION

When pressurised fluid from the clutch master

cylinder acts upon the seal (1), the seal moves,

stroking the sleeve (2) before it. As the throwout

bearing assembly (3) is attached to the sleeve (2),

the throwout bearing also moves with the sleeve, to

forc e the diaphragm f ingers of the pr es sur e plate to

move against its in-built spring force.

As the slave cylinder sleeve (2) continues to be

moved along the guide of the cylinder body (4), the

force applied to the pressure plate diaphragm

spring caus es the s pr ing to pivot, thus r eleasing the

applied force on the clutch driven plate, allowing it

to spin. When this situation occurs, the frictional

link between the engine flywheel and the

transmission input shaft is broken and gear

changing can then saf ely tak e place, without undue

stress being placed upon the transmission

synchromesh assemblies.

When the clutch pedal is released, the pressure

plate diaphragm spring force, moves the throwout

bearing (3) and slave cylinder sleeve (2), back

along the slave cylinder body guide (4), returning

displaced fluid back to the master cylinder

reservoir.

Coil spring (5) acts to maintain constant contact of

the throwout bearing with the pressure plate

diaphragm spring fingers, thereby reducing pedal

travel to begin initial movement by compensating

for any slight finger height variation in the

diaphragm spring.

As the clutch pressur e plate is self-adj usting, the ‘at

rest’ position of the throwout bearing and clutch

slave cylinder sleeve (2), remains relatively

constant throughout the life of the assembly,

compared to other clutch control systems.

Figure 7A1-4

3. SERVICE OPERATIONS

3.1 FLUID LEVEL CHECK

Check that the fluid level is between the two

guidelines on the translucent reservoir housing.

Should the addition of f luid be required, rem ove the

reservoir cap and use heavy duty brake fluid to

DOT 4+ (SAE J1704).

Figure 7A1-5

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3.2 CLUTCH HYDRAULIC SYSTEM, BLEED

The clutch hydraulic system m ust be bled whenever the hydraulic line has been disconnected, or when a leak has

allowed air to enter the system. Air trapped in the system can prevent full disengagement of the clutch.

During bleeding operations, the master cylinder reservoir must be kept at least half full with hydraulic brake fluid.

1. Carefully clean any dirt from around the fluid

reservoir cap.

2. Remove the filler cap and top up reservoir as

required, with heavy duty hydraulic brake fluid

to DOT 4+ (SAE J1704).

3. Using an 11 mm, 3/8 drive socket, short

extension and socket bar, loosen the slave

cylinder bleeder, located in the upper aperture

of the transmission adaptor plate/clutch

housing, on the left hand side.

4. Then, using just the socket and extension,

tighten the bleeder, using light finger force

only .

5. Insert the end of the rubber tube of Tool

AU529 over the end of the bleeder, positioned

at the 9 o’clock position.

6. W ith the other end of the bleeder tool inserted

into a clean glass c ontainer such as a jar , that

has been partially filled with new brake fluid,

open the bleeder 1/4 turn, using the rubber on

the bleeder tool to provide the required grip.

Ensure that the end of the hose always

remains submerged in the brake fluid during

bleeding operations.

7. Using an assistant, slowly depress the clutch

pedal by hand, one single time and, while

holding the pedal depressed, close the bleeder

using Tool AU529. O nc e the bleeder is c losed,

the clutch pedal can be slowly released.

Repeat this process until all bubbles cease to

appear at the end of the bleeder hose.

NOTE: Do not pump the clutch pedal repeatedly

during bleeding operations, as entrapped air will

cause the fluid to foam, making air removal

extremely difficult. Als o as the hydraulic steel piping

is routed over the top of the transmission housing,

air can be trapped in this section.

8. When all the air has been removed, close off

the bleeder and remove T ool AU 529. With the

clutch pedal still depressed, tighten the

bleeder screw to the correct torque

specification.

CLUTCH SLAVE CYLINDER

BLEEDER SCREW 15 - 20 Nm

TORQUE SPECIFICATION

9. Once all bleeding operations have been

completed, ensure that the fluid level in the

reservoir is correct.

Figure 7A1-6

NOTE: Alternative methods of bleeding would be to

use either a pressure bleeder, with a commercially

available res ervoir cap or use the vacuum m ethod,

with the assistance of a hand operated vacuum

pump such as Tool No. J23738-A (also

commercially available as a ‘MityVac’) and an

airtight, glass container.

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3.3 CLUTCH MASTER CYLINDER

For all service operations relating to the m aster cylinder fitted to GEN III V8 engined, VT Ser ies II vehicles, refer to

Section 7A CLUTCH, of the VT Series I Service Information.

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3.4 CLUTCH S LAVE CYLINDER

REMOVE

1. Remove the transmission from the vehicle.

See 4.2 TRANSMISSION ASSEMBLY

Remove, in Section 7B3 MANUAL

TRANSMISSIO N - GEN III ENGINE, of the VT

Series I Service Information, for details.

2. Unscrew the pipe fitting (1) from the clutch

slave cylinder (2).

3. Remove the two bolts (3) securing the clutch

slave cylinder assembly to the transmission

adaptor plate, then remove the slave cylinder.

DISASSEMBLE

If required, remove the throwout bearing. Refer

3.5 THROWOUT BEARING Replace, in this

Section. Apart from this bearing and the spring

behind it, there are no other serviceable par ts in the

clutch slave cylinder assembly.

CLEAN AND INSPECT

IMPORTANT: Do not wash hands in petrol or oil

before cleaning or handling clutch slave cylinder

parts. Always use a soap and water based hand

cleaning product.

1. Inspect the slave cylinder for any evidence of

fluid leakage. If found, replace the assembly.

2. Remove the bleeder screw and inspect the

slave cylinder threaded apertures for dam age,

re-claiming with thread inserts as required or

replace the assembly.

3. Check that the bleeder screw thread is

undamaged and that the drilled passage is

clear of debris.

4. Check the throwout bearing for any signs of

roughness or dryness by rotating the bearing

when a light load is applied. If either of these

conditions are evident, replace the clutch slave

cylinder assembly.

Figure 7A1-7

REINSTALL

Installation is the reverse of removal

operations except for the following points:

1. Install slave cylinder and the 2 retaining bolts,

then tighten the bolts to the correct torque

specification.

CLUTCH SLAVE CYLINDER BOLT

TORQUE SPECIFICATION 7.5 - 12.5 Nm

2. Install and tighten hydraulic pipe flare nut to

the slave cylinder, tightening to the correct

torque specification.

HYDRAULIC PIPE FLARE NUT TO

SLAVE CYLINDER 12 - 14 Nm

TORQUE SPECIFICATION

3. Reinstall the transmission. Refer to

4.2 TRANSMISSION ASSEMBLY Reinstall in

Section 7B3 MANUAL TRANSMISSION -

GEN III ENGINE, of the VT Series I Service

Information, for details.

4. Bleed the clutch hydraulic system, as detailed

in 3.2 CLUTCH HYDRAULIC SYSTEM,

BLEED, in this Section.

5. Following bleeding operations, check that the

hydraulic fluid level is correct, as detailed in

3.1 FLUID LEVEL CHECK, in this Section.

6. Road test the vehicle and check for correct

clutch and transmission operation.

3.5 CLUTCH THROWO UT BEARING

REPLACE

1. Remove the clutch slave cylinder assembly.

See 3.4 CLUTCH SLAVE CYLINDER

Remove, in this Section.

2. While holding the body of the slave cylinder

with one hand, grasp the throwout bearing with

the other and pull, while twisting the bearing

back and forth.

Figure 7A1-8

IMPORTANT: Do not use c leaners or c hemicals on

the bearing guide sleeve and do not apply any

grease to the sleeve.

3. Using a clean dry rag, wipe the exposed

portion of the bearing guide sleeve.

NOTE: DO NOT apply grease to the new clutch

throwout bearing as it has already been greased.

4. Install a new clutch throwout bearing to the

guide sleeve, by firmly pushing the new

bearing onto the sleeve, until it snaps into

place over the retaining tab.

5. Reinstall the clutch slave cylinder assembly.

Refer to 3.4 CLUTCH SLAVE CYLINDER,

Reinstall, in this Section.

Figure 7A1-9

3.6 CLUTCH P EDAL

Refer to 3.5 CLUTCH PEDAL, Remove/Reinstall in Sec tion 7A CLUT CH, of the VT Ser ies I Service Infor m ation f or

this procedure.

3.7 CLUTCH PE DAL SWITCH

REMOVE

CAUTION: Disable the SRS (Air Bag). Refer to

'DISABLING THE SRS’, Section 12M, SRS of

this Service Information.

1. Disconnect the battery earth cable.

2. From inside the passenger compartment,

remove the lower the instrument panel, right

hand cover assembly 1), as follows;

Grasp the top edge of the cover (1) on each

side of the s teering column with the finger tips

and pull outwards, to fr ee the r etaining lugs ( 2)

from the clips.

Prise out the left hand hinge pin (3) with a

screwdriver or similar tool and remove.

Tilt the panel down on the left hand side and

disengage the right hand side hinge pin.

Figure 7A1-10

3. If fitted, remove the instrument panel lower

trim by removing the two fasteners and

retainer. Lower the panel sufficient to gain

access to the footwell illum ination lamp holder

(if f itted), then twist the lamp holder to rem ove

from the trim.

Figure 7A1-11

4. Remove screws attaching the fuse and Body

Control Module (BCM) panel to the dash

panel. Leaving the Data Link Connec tor (DLC)

attached to the panel, swing the panel to one

side and secure with tie wire or similar.

Figure 7A1-12

5. Remove the clutch switch wiring harness

connector (1), then remove the clutch switch

(2) by rotating counter -clock wise  turn to free

the switch bayonet lugs.

Figure 7A1-13

REINSTALL

1. Install the switch and rotate  turn clockwise

to lock the switch bayonet lugs, then reinstall

the wiring harness connector.

2. Reinstall all removed instrument panel

components in the reverse to removal

operations.

3. Road test vehicle to check clutch switch

operation. Refer to Section 12E CRUISE

CONTROL of the VT Series II Service

Information.

IMPORTANT: Enable the SRS (Air Bag). Refer to

'ENABLING THE SRS’, Section 12M, SRS of the

VT Series I Service Information.

3.8 CLUTCH AND PRESSURE PLATES

REMOVE

1. Remove transmission assembly (1). Refer to

Section 7B3 MANUAL TRANSMISSION -

GEN III ENGINE of the VT Series II Service

Information.

Figure 7A1-14

2. Initially loosen all pressur e plate retaining bolts

(4), working from opposite sides, to avoid

distortion of the cover (3).

3. Continue loosening bolts from opposite sides,

until all are rem oved, then lift the c lutch driven

plate (2) and pressure plate (3) assemblies

from the flywheel (1).

NOTE: The two locating dowel pins in the flywheel

are set 170° apart, which means that marking the

pressure plate relationship to the flywheel is not

required.

Figure 7A1-15

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INSPECT

1. Wipe pressure plate and flywheel surfaces

clean using a soft cloth dampened with a

suitable cleaning solvent (do not use

petroleum based products).

NOTE: Do not wash the pressure plate assembly -

blow dust out with compressed air.

2. With the two slave cylinder fluid apertures

firm ly plugged, clean the assem bly by blowing

off with compressed air. Do not use any

petroleum based products for cleaning.

NOTE: Do not attempt to clean the slave cylinder

and throwout bearing with any fluid solvents. Only

blow off with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury and breathing apparatus with a suitable

filter for both of these cleaning operations.

3. Inspect input shaft spigot bush for wear. If

necessa ry, replace the bush as detailed in this

Section.

NOTE: Do not remove the bush unless inspection

reveals that replacement is required.

4. Inspect the slave cylinder for any evidence of

fluid leakage. If found, replace the assembly.

5. Remove the bleeder screw and inspect the

slave cylinder threaded apertures f or dam age,

re-claiming with thread inserts as required or

replace the assembly.

6. Check that the bleeder screw thread is

undamaged and that the drilled passage is

clear of debris.

7. Check the throwout bearing for any signs of

roughness or dryness by rotating the bearing

when a light load is applied. If either of these

conditions are evident, replace the clutch

slave cylinder assembly.

8. Inspect flywheel and clutch pressure plate

friction surfaces for burn marks scoring or

roughness. Slight roughness may be

smoothed with fine emery cloth.

Scoring of flywheel or pressure plate surfaces

will require replacement of the damaged

component/s.

9. Inspect clutch driven plate for lining wear or

other damage, such as oil or fluid

contamination.

NOTE: If oil or fluid is found on the clutch linings,

locate and correct the cause of the leak before

proceeding with any clutch repairs.

10. Bef ore installing the clutch driven plate, check

clutch hub for a free sliding fit on maindrive

gear clutch shaft splines.

PRESSURE PLATE ADJUSTMENT

IMPORTANT: Prior to the installation of the

pressure plate, the self-adjusting feature must be

pre-set. If not carried out before installation, then

probable failure of the pressure plate will result.

1. Place the flat side of the clutch plate

downwards on flat press plates, then place the

pressure plate assembly over it.

2. Compress the pressure plate diaphragm

spring until tension is realised from the clutch

driven plate.

3. Hold two screwdrivers or other suitable tools,

placing them against 2 of the 3 stepped

adjusting ring tension spring stops , jus t in front

of the adjusting ring tension springs.

Figure 7A-16

4. Using the screwdrivers, rotate the stepped

adjusting ring, counter-clockwise (arrow), fully

compressing the tension springs.

5. While holding the tension springs in the fully

loaded position, release the force on the

diaphragm spring. This will then retain the

springs in the fully loaded position.

6. Remove the pressure plate and clutch driven

plate from the press.

Figure 7A-17

REINSTALL

1. Sparingly apply 10% molybdenum disulphide

grease, such as Molybond GA 10 (or

equivalent to Holden’s Specif ication HN 1271),

to the bearing face of the clutch throwout

bearing, input shaft splines and spigot.

2. W hile holding the clutch driven plate up to the

engine flywheel, insert a suitable clutch

centring tool (commercially available) into the

spigot bearing, through driven plate.

NOTE: The c lutch driven plate is installed with

the flat side of the hub, facing forward to the

flywheel. The word ‘Flywheel Side’ is also

stamped on the inner surface, as shown.

Figure 7A-18

3. Install the pressure plate assembly (1) over

the alignment tool (4) and clutch driven plate

(2), aligning the offset dowel pins in the

flywheel (3) with the mating holes in the

pressure plate cover (1).

4. Loosely install the 6, pressure plate to flywheel

bolts (5).

Figure 7A-19

5. Tighten the 6 pressure plate retaining bolts in

sequence and evenly over 4 stages until the

correct torque specification is reached.

CLUTCH PRESSURE Stage 1: 15 Nm

PLATE BOLT Stage 2: 35 Nm

TORQUE Stage 3: 55 Nm

SPECIFICATION Stage 4: 70 Nm

IMPORTANT: Tightening to the torque settings,

stages and in the sequence listed are all

necessary, to avoid permanent distortion of the

pressure plate cover.

Figure 7A-20

6. Reinstall the transmission assembly. Refer to

Section 7B3 MANUAL TRANSMISSION,

GEN III V8 ENGINE of the VT Series II

Service Information.

NOTE: When installing the transmission, do not

allow it to ‘hang’ on the maindrive gear splines, as

the clutch driven plate will be damaged.

7. Bleed the hydraulic clutch actuating system.

See 3.2 CLUTCH HYDRAULIC SYSTEM,

BLEED, in this Section.

8. Depress the clutch pedal several times to

allow the self-adjusting function of the

pressure plate to take effect.

9. Start engine, and check for exhaust leaks

before road testing the vehicle for satisfactory

clutch operation.

Figure 7A-21

3.9 ENGINE FLYWHEEL

NOTE: This operation is also included in the

engine mechanical items

3.5 ENGINE FLYWHEEL/FLEXPLATE in Section

6A3 ENGINE MECHANICAL - GEN III ENGINE, of

the VT Series II Service Information) but, as this

component forms an integral part of the clutch

assembly and the driveline, it has also been

included here.

REMOVE

1. Disconnect battery earth lead.

2. Remove the starter motor. Refer

Section 6D3-2 STARTING SYSTEM - GEN III

ENGINE of the VT Series II Service

Information.

3. Remove manual transmission and the clutch

assembly, refer to Section 7B3, MANUAL

TRANSMISSION - GEN III ENGINE of the VT

Series II Service Information and

3.8 CLUTCH AND PRESSURE PLATES in

this Section.

IMPORTANT: Note the position and direction of

the engine flywheel before removal. The flywheel

does not use a locating pin for alignment. Mark or

scribe the end of the crankshaft and the flywheel

before component removal. The engine flywheel

must be reinstalled to the original position and

direction.

The engine flywheel will not initially seat against the

crankshaft flange, but will be pulled onto the

crankshaft by the engine flywheel bolts. This

procedure requires a three stage tightening

process.

If replac ing the engine f lywheel, note the location of

any existing balance weights (relative to the

position of the flywheel locating hole). Install new

balance weights into the new flywheel (if

applicable). Flywheel balance weights must be

installed into the new flywheel in the same location

as the old flywheel. A properly installed balance

weight will be either flush or below flush with the

machined flywheel surface.

4. Install the ring gear holding Tool No. J 42386-

A, using the two starter motor bolts. Tighten

both bolts to 50 Nm.

NOTE: Ensure that the teeth of the holding tool

engage correctly with the ring gear teeth , before

tightening the fasteners.

Figure 7A1-22

Techline

5. Mark or scribe the end of the crankshaft and

the flywheel. Remove the engine flywheel

bolts, after loosening in an opposite sequence.

6. Remove the engine flywheel from the

crankshaft.

Figure 7A1-23

CLEAN AND INSPECT

1. Clean the flywheel in a suitable solvent and

blow dry with compressed air.

CAUTION: Wear safety glasses to avoid eye

injury.

2. Inspect the flywheel for loose or improperly

installed balance weights (if applicable). A

correctly installed balance weight should be

either flush or below the m ac hined s urface of

the flywheel.

3. Inspect the flywheel for the following:

a. Pitted surfaces (1).

b. Grooves or scoring (2).

c. Rusted surface (3).

d. Damaged ring gear teeth (4).

e. Loose or incorrectly positioned ring

gear. The ring gear is an interference

fit onto the flywheel and should be

positioned completely against the

flange of the flywheel.

f. Missing, bent or damaged pressure

plate locating pins. The two locating

pins are pressed into the flywheel and

are spaced 170° apart.

Figure 7A1-24

REINSTALL

1. If replacing a flywheel;

a. Install any balance weights, as required.

b. Use the flywheel locating hole as

reference and scribe an alignment mark

corresponding to the one on the original

flywheel.

2. Install the flywheel, aligning the scribed marks

on the crankshaft and flywheel.

Figure 7A1-25

3. Loosely install NEW flywheel bolts, tightening

in the sequence shown in Figure 7A1-25, to an

initial torque specification of 20 Nm.

4. Reinstall the ring gear holding Tool No. J

42386-A, using the two starter motor bolts.

Tighten both bolts to 50 Nm.

NOTE: Ensure that the teeth of the holding tool

engage correctly with the ring gear teeth , before

tightening the fasteners.

Figure 7A1-26

5. Continue to tighten the flywheel bolts in the

sequence shown, in two additional stages and

to the correct torque specification.

FLYWHEEL BOLTS Stage 2: 50 Nm

TORQUE SPECIFICATION Stage 3: 100 Nm

Figure 7A1-27

6. Reinstall clutch assembly and manual

transmission, refer to 3.8 CLUTCH AND

PRESSURE PLATES in this Section and

Section 7B3, MANUAL TRANSMISSION -

GEN III ENGINE of the VT Series II Service

Information.

7. Reconnect battery earth lead.

8. Check starter motor operation and road test

vehicle to check transmission and clutch

operation.

3.10 RING GEAR

REPLACE

Automatic Transmission:

The ring gear is welded to the flexplate and is

serviced only as an assembly. Refer to

Section 6A3 ENGINE MECHANICAL, GEN III

ENGINE, of the VT Series II Service Information.

Manual Transmission:

1. Remove flywheel, refer to 3.9 ENGINE

FLYWHEEL, in this Section.

2. After marking with a centre punch and

hammer, drill an 8 mm diameter hole through

the ring gear, between two teeth.

Figure 7A1-28

3. Secure the flywheel in a vice fitted with soft

jaws, then use a sharp cold chisel and

hamm er to split the ring gear at the drill point.

Remove the ring gear from the flywheel.

Figure 7A1-29

4. Check that there are no burrs or foreign

material on the new ring gear and flywheel

mating surfaces. If present, burrs can be

removed with a fine mill file.

5. Heat and shrink the replacement ring gear,

using either one of the next two methods;

1.1 Heat the new ring gear, uniformly in an

oven to a temperature between 180 -

230° C. This temperature can be

achieved by using a thermal indicating

crayon such as Faber-Castell

Thermocrom 2815-200.

2.1 Polish several places on the ring gear

using emery cloth.

2.2 Use a hot plate or a slowly moving torch

to heat the ring gear until the polished

spots turn blue (approximately 300° C).

NOTE: Heating the ring gear above 427°

C will destroy the ring gear teeth heat

treatment.

6. Using protective gloves and two pairs of pliers,

quick ly place the ring gear against the f lywheel

shoulder. Allow the ring gear to cool until it

contracts and is firmly held in place.

7. Reinstall flywheel. Refer to

3.9 ENGINE FLYWHEEL, in this Section.

8. Reconnect battery earth lead and check

starter motor operation.

3.11 CRANKSHAFT SPIGOT BUSH

REPLACE

1. Disconnect battery earth lead.

2. Remove manual transmission and the clutch

assembly, refer to Section 7B3, MANUAL

TRANSMISSION - GEN III ENGINE of the VT

Series II Service Information and

3.8 CLUTCH AND PRESSURE PLATES in

this Section.

3. Using Tool J 23907, (also released as Tool

6A22-2 and slide hammer 7A28) or

commercial equivalent, remove the spigot

bush from the rear of the crankshaft.

Figure 7A1-30

4. Check that the rear crankshaft oil gallery plug

is not a loose fit, damaged or leaking.

5. If replacement is required, apply sealant such

as Loctite 242 or equivalent, to the sides of a

new plug and install to the correct depth.

Crankshaft Rear Oil gallery Plug Depth Specification

Distance ‘A’............................. 31.2 - 31.6 mm

Figure 7A1-31

6. Using a suitable, stepped (or piloted ) driver

such as Tool J 38836 and flat washer (2),

install a replacement bush (1) to the rear of

the crankshaft, until flush with the crankshaft

counter-bore, as shown.

7. Lubricate the bearing with a small amount of

SAE 90 gear oil.

8. Reinstall clutch assembly and manual

transmission, refer to 3.8 CLUTCH AND

PRESSURE PLATES in this Section and

Section 7B3, MANUAL TRANSMISSION -

GEN III ENGINE of the VT Series II Service

Information.

9. Reinstall the starter motor. Refer

Section 6D3- 2 ST ARTING SY STEM - GEN III

ENGINE of the VT Series II Service

Information.

10. Reconnect battery earth lead.

11. Check starter motor operation and road test

vehicle to check transmission and clutch

operation.

Figure 7A1-32

4. DIAGNOSIS

CONDITION PROBABLE CAUSE CORRECTIVE ACTION

SLlPPING Worn or oil-soaked lining.

Driven plate sticking on transmission

input shaft splines.

Weak or broken diaphragm spring

Master or slave cylinder defective

Replace driven plate, correct oil leak.

Clean splines and appl

10%

mol

bdenum disulphide

rease to

Holden’s Specification HN 1271.

Replace pressure plate assembl

Refer Operation 3.8 Clutch and

Pressure Plates, in this Section.

Overhaul defective cylinder as outlined

under 3.3 Master Cylinder or 3.4 Clutch

Slave Cylinder, in this Section.

DRAG OR FAILURE TO RELEASE Air trapped in hydraulic system.

Leak In hydraulic system.

Clutch master or slave cylinder

defective.

Cracked or oil-soaked linings.

Excessive driven plate run-out or

distorted.

Driven plate sticking on splines.

Transmission input shaft spigot

partially seized in crankshaft spigot

bush.

Bleed system as outlined under 3.2

Clutch Hydraulic System Bleed, in this

Section.

Correct leak and bleed hydraulic

system.

Replace defective cylinder as outlined

under 3.3 Master Cylinder or 3.4 Clutch

Slave Cylinder, in this Section.

Replace driven plate. Refer Operation

3.8 Clutch and Pressure Plates, in this

Section.

Replace driven plate. Refer Operation

3.8 Clutch and Pressure Plates, in this

Section.

Clean and free splines and apply 10%

molybdenum disulphide grease to

Holden’s Specification HN 1271.

Remove clutch, Iubricate or replace

bush. Refer Operation 3.10 Crankshaft

Spigot Bush, in this Section.

GRAB OR CHATTER Oil on linings.

Worn transmission input shaft splines.

Rou

h, or

rooved, fl

wheel o

pressure plate.

Loose engine mountings.

Loose or worn universal joints or loose

rear universal joint flange.

Defective clutch driven plate.

Replace driven plate, correct oil leak.

Replace transmission input shaft. Refer

Section 7B3 TRANSMISSION of the

VT Series II Service Information.

Replace fl

wheel or replace both

wheel and pressure plate. Refe

Operation 3.8 Clutch and Pressure

Plates or 3.9 En

ine Fl

wheel, in this

Section.

hten or replace mountin

s. Refe

Section 6A3 ENGINE MECHANICAL

GEN III V8 ENGINE of the VT Series II

Service Information.

hten or replace universal

oint/s

and/or flan

e. Refer 4C PROPELLER

SHAFT AND UNIVERSAL JOINTS of

the VT Series I Service Information.

Replace clutch driven plate. Refer

Operation 3.8 Clutch and Pressure

Plates, in this Section.

HARD OR STIFF CLUTCH ACTlON Clutch pedal bush seized or ti

ht on

pedal shaft.

Blockage in fluid hydraulic pipe.

Replace bushes as detailed in 3.6

Clutch Pedal in this Section.

Clean lines and bleed hydraulic

system. Refer 3.2 Clutch Hydraulic

System Bleed in this Section.

CLUTCH ENGAGEMENT TOO SLOW Blocka

e in fluid h

draulic pipe.

Clutch master or slave c

linde

defective.

Incorrect brake fluid used.

Clean lines and bleed h

draulic

stem. Refer 3.2 Clutch H

draulic

System Bleed in this Section.

Replace defective cylinder as outlined

under 3.3 Master Cylinder or 3.4 Clutch

Slave Cylinder, in this Section.

Flush and bleed hydraulic system.

Refer 3.2 Clutch Hydraulic System

Bleed in this Section.

5. SPECIFICATIONS

NOTE: Only those specifications relating specifically to this Section are quoted here. For all remaining

specifications, refer to Section 7A CLUTCH, of the VT Series I Service Information.

MASTER CYLINDER:

.................................................................................... All Engines

Type .................................................................................... Compensating port.

Bore Size............................................................................... 19.05 mm

Nominal Stroke...................................................................... 30 mm

CLUTCH SLAVE CYLINDER:

Type .................................................................................... Concentric hydraulic slave cylinder with side feed

....................................................................................and bleed ports

Bore Size............................................................................... I.D. 36 mm/O.D 47.6 mm (nominal)

Available Stroke .................................................................... 22.8 mm (nominal)

BRAKE FLUID:

Type .................................................................................... To Holden’s Specification HN 1796.

CLUTCH DRIVEN PLATE:

Type .................................................................................... Single plate dry disc.

Disc Facing:

Outside Diameter ............................................................... 297 mm

Inside Diameter.................................................................. 198 mm

Thickness of disc assembly with 10,000 N load applied.... 8.7 ± 0.35 mm

CLUTCH PRESSURE PLATE:

Type .................................................................................... Self-adjusting with a recessed nodular iron plate,

with a pressed steel cover plate and a multi-

fingered Belleville diaphragm spring.

CLUTCH THROWOUT BEARING:

Type .................................................................................... Ball race.

Lubrication............................................................................. Sealed with grease for life.

LUBRICANT:

Face of throwout bearing/transmission input shaft splines ... 10% Molybdenum Disulphide or equivalent to

Holden’s Specification HN 1271.

6. TORQUE WRENCH SPECIFI CATIONS

NOTE: Only those torque specifications referred to in this Section are quoted here. For all remaining torque

specifications, refer to Section 7A CLUTCH, of the VT Series I Service Information. Nm

Clutch pressure plate bolt to flywheel Stage 1........................................... 15

Stage 2........................................... 35

Stage 3........................................... 55

Stage 4........................................... 70

Clutch slave cylinder bleed screw .................................................................. 15 - 20

Clutch slave cylinder mounting bolt................................................................ 7.5 - 12.5

Flywheel to crankshaft mounting bolts Stage 1........................................... 20

Stage 2........................................... 50

Stage 3........................................... 100

Hydraulic pipe flare nut to slave cylinder and flexible hose............................ 12 - 14

Master cylinder hydraulic pipe to flexible hose flare nut................................. 12 - 14

7. SPECIAL TOOLS

TOOL No. REFERENCE

IN TEXT TOOL DESCRIPTION COMMENTS

AU529 CLUTCH SLAVE CYLINDER BLEED TOOL New release.

Used to bleed air from the

Central Slave Cylinder (CSV)

fitted to the T56, 6 speed

manual transmission available

for the GEN III V8 engine.

J 23907 SLIDE HAMMER/BUSHING REMOVER Previously released.

Used to remove the crankshaft

spigot bush.

Also released as remover,

6A22-2 and slide hammer,

7A28.

J 38836 PILOTED DRIVER

T6A3 189b

New release.

Also used for the same

operation in Section 6A3,

Engine Mechanical GEN III, of

the VT Series II Service

Information.

J 42386-A RING GEAR HOLDING TOOL New release.

Also used for the same

operation in Section 6A3,

Engine Mechanical GEN III, of

the VT Series II Service

Information.

N/A CLUTCH CENTRING TOOL Commercially available.