How to Install a Clutch Disk

What You'll Need
13 millimeter socket, 17 millimeter socket, 6 millimeter socket hex bit
Mechanic's pick - curved end
Small pry bar or flat blade screwdriver
Dead blow hammer
75-90W gear oil
Compressed air
Impact wrench, torque wrench

A clutch disk is a steel plate that is covered with friction material. This material goes between the flywheel and pressure plate. The friction material will vary according to whether the clutch is wet or if it is dry. If it is wet, energy to the liquid will be lost. If it is dry, then it is not drenched with fluids. When the clutch is in use, the disk is pressed between the flywheel and the pressure plate. The disk's hub transmits power to the engine. If a clutch disk gets worn out, your car may as well be dead because it will not be able to function. Sometimes, multiple clutch disks can be stacked to make up for lower friction. This disk is similar to brake pads since it is made from a high friction material. This also eliminates slipping while fully functional. Installing a clutch disk can be an easy do it yourself project. The tools needed and step-by-step guide to perform this project is listed below.

Step 1 – Remove Differential

Remove and drain gear oil from the differential. Use the 17 mm hex head bolts to remove the rear cover. Remove the output shafts this may require apry bar. Remove the outer bearing housing using the 13 mm hex head bolts. Tap the differential housing to remove them.

Step 2 – Remove the Internal Parts

Pull the limited slip assembly out from the house and stand it with the cover plate facing upward. Remove the screws holding in the cover plate. Be careful not to strip them. You will now remove the clutch disks, gear clusters and friction surfaces. Remember how you remove them so that you can stack them in the same order when it is time to place them back. 

Step 3 – Install the Clutch Disk

When you install the clutch disks, make sure they have a dog ring friction disk adjacent to them. You will want to make sure they have a fresh friction surface, so flip them. Install the clutch disk against the fly wheel. The rivet heads should be facing the engine. Then, install the floater plate. You can reinstall the internal components by reversing the order of how you took them out. 

Step 4 – Replace Internal Parts

Return the internal assembly back into the case. Hold the assembly and rotate the input shaft in so that it can be meshed with the ring gear. While doing this, place the outer bearing race covers back in the sides of the case. Put the 13 mm hex head bolts back in. Put the cover back on with the 17 mm hex head bolts. Tighten them down and fill with the oil.