Clutch

Document ID: 1985049 Page 1 of 1
2009 Cadillac CTS | CTS (VIN D) Service Manual | Transmission | Clutch | Specifications |
Document ID: 1985049
Fastener Tightening Specifications

Specification
Application Metric English
Clutch Pedal Assembly to Brake Pedal Assembly Nuts 20 N·m 15 lb ft
Clutch Pedal Assembly to Cowl Nut 9 N·m 80 lb in
Clutch Pedal Assembly Bolt 20 N·m 15 lb ft
Clutch Pedal Position Switch Bolt 2.5 N·m 22 lb in
Clutch Pressure Plate Bolt 28 N·m 21 lb ft
Concentric Slave Cylinder Bolt 20 N·m 15 lb ft
Concentric Slave Cylinder Quick Connector Bolt 10 N·m 89 lb in
© 2010 General Motors Corporation. All rights reserved.
http://localhost:9001/si/showDoc.do?docSyskey=1985049&pubCellSyskey=10462&pubO... 10/4/2010
2009 Cadillac CTS | CTS (VIN D) Service Manual | Transmission | Clutch | Specifications |
Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United States Canada
Clutch Hydraulic Fluid DOT 4 Hydraulic Fluid 88958860 88901244
2009 Cadillac CTS | CTS (VIN D) Service Manual | Transmission | Clutch | Repair Instructions |
Clutch Pedal Replacement

Removal Procedure
1. Remove the driver side instrument panel (I/P) insulator. Refer to Instrument Panel Insulator
Replacement - Left Side.
2. Remove the parking brake pedal assembly. Refer to Parking Brake Lever Pedal Assembly
Replacement.
3. Disconnect the clutch pedal position switch electrical connector.
4. Disconnect the clutch master cylinder push rod (1) from the clutch pedal pin (2).
5. Remove the clutch fluid reservoir (1) from the cowl.

6. Position the clutch fluid reservoir aside.
7. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
Note: Do NOT disconnect the hydraulic hoses from the clutch master cylinder.
8. Rotate the clutch master cylinder (2) clockwise 1/8 turn.

9. Remove the clutch master cylinder (2) from the cowl.
10. Remove the park brake pedal assembly from the I/P and position aside. Refer to Parking
Brake Lever Pedal Assembly Replacement.
11. Remove the wiring harness connector (1) from the clutch pedal position sensor.
12. Remove the wiring harness retainer (2) from the clutch pedal assembly.
13. Remove the 2 bolts (1) securing the clutch pedal assembly to the I/P carrier.
14. Remove the 2 nuts (2) securing the clutch pedal assembly to the brake pedal assembly.
15. Remove the nut (3) securing the clutch pedal assembly to the cowl.
16. Remove the clutch pedal assembly (1) from the vehicle.
Installation Procedure
1. Install the clutch pedal assembly (1) to the vehicle.
Caution: Refer to Fastener Caution in the Preface section.
2. Install the nuts (2) securing the clutch pedal assembly to the brake pedal assembly and
tighten to 20 N·m (15 lb ft).
3. Install the nut (3) securing the clutch pedal assembly to the cowl and tighten to
9 N·m (80 lb in).
4. Install the 2 bolts (1) securing the clutch pedal assembly to the I/P carrier and tighten to
20 N·m (15 lb ft).
5. Install the wiring harness retainer (2) to the clutch pedal assembly.
6. Install the wiring harness connector (1) to the clutch pedal position sensor.
7. Install the park brake pedal assembly. Refer to Parking Brake Lever Pedal Assembly
Replacement.
8. With the clutch fluid reservoir connection at 2 o'clock position. Insert the clutch master
cylinder (2) into the cowl.
9. Align the keys of the clutch master cylinder housing with the tabs on the clutch pedal
bracket.
10. Rotate the clutch master cylinder (2) counter clockwise approximately 1/8 turn until fully
seated. The clutch fluid reservoir hose connection will be at vertical 12 o'clock position when
the clutch master cylinder is properly installed.
11. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
12. Install the clutch fluid reservoir (1) to the cowl.
13. Position the clutch master cylinder push rod (1) to the clutch pedal pin (2).
14. Push the clutch master cylinder push rod (1) onto the clutch pedal pin (2) to secure.
15. Check for proper clutch pedal movement and operation.
16. Install the parking brake pedal assembly. Refer to Parking Brake Lever Pedal Assembly
Replacement.
17. Install the driver side I/P insulator. Refer to Instrument Panel Insulator Replacement - Left
Side.
Warning: Replacement or reprogramming of the ECM, or replacement of the clutch pedal

position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed.
Failure to perform the CPPS learn procedure may result in personal injury or damage to the
vehicle or its components if the vehicle is in gear and the starter motor is accidentally
engaged.
18. Perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal Position
Sensor Learn.
Clutch Return Spring Replacement

Removal Procedure
1. Remove the closeout/insulator panel. Refer to Instrument Panel Insulator Replacement - Left
Side .
2. Disconnect the clutch master cylinder push rod from the clutch pedal pin.
3. Carefully bend the clutch spring retaining tab (1) to the side only far enough to provide
clearance for clutch spring removal.
4. Remove the clutch pedal return spring from the clutch pedal assembly as follows:
4.1. Remove the center of the spring from the center spring bushing.
4.2. Remove the outer ears of the spring from the outer spring bushings.
5. Remove the clutch pedal return spring bushings from the clutch pedal assembly.
1. Install the clutch pedal return spring bushings to the clutch pedal assembly.
Important: Correct spring orientation is critical for proper clutch pedal operation.
2. Install the clutch pedal return spring to the clutch pedal assembly as follows:
2.1. Insert the outer ears of the spring into the outer spring bushings.
2.2. While holding the clutch pedal fully depressed to the floor place the center of the spring
into the center spring bushing.
3. Move the clutch pedal through the full range of motion to check for proper clutch pedal spring
operation.
4. Carefully bend the clutch spring retaining tab (1) back to the original position in order to
retain the clutch spring.
5. Connect the clutch master cylinder push rod to the clutch pedal pin.
6. Install the closeout/insulator panel. Refer to Instrument Panel Insulator Replacement - Left
Side .
Clutch Master Cylinder Replacement

Removal Procedure
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface
section.
1. Remove the driver side instrument panel insulator. Refer to Instrument Panel Insulator
2. Disconnect the clutch pedal position switch electrical connector.
3. Disconnect the clutch master cylinder push rod (1) from the clutch pedal pin (2).
4. Remove the clutch fluid reservoir (1) from the cowl.

5. Position the clutch fluid reservoir aside.
6. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
Note: Do NOT disconnect the hydraulic hoses from the clutch master cylinder.
7. Rotate the clutch master cylinder (2) clockwise 1/8 turn.

8. Remove the clutch master cylinder (2) from the cowl.
9. Remove the park brake pedal assembly from the instrument panel and position aside. Refer
to Parking Brake Lever Pedal Assembly Replacement.
Note: Install a rubber cap over the exposed hose fitting in order to prevent fluid loss and
contamination.
10. Disconnect the clutch hydraulic hose. Refer to Hydraulic Clutch Hose/Pipe Replacement.
1. Connect the clutch hydraulic hose. Refer to Hydraulic Clutch Hose/Pipe Replacement.
2. With the clutch fluid reservoir connection at 2 o'clock position. Insert the clutch master
cylinder (2) into the cowl.
3. Align the keys of the clutch master cylinder housing with the tabs on the clutch pedal
bracket.
4. Rotate the clutch master cylinder (2) counter clockwise approximately 1/8 turn until fully
seated. The clutch fluid reservoir hose connection will be at vertical 12 o'clock position when
the clutch master cylinder is properly installed.
5. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
6. Install the clutch fluid reservoir (1) to the cowl.
7. Position the clutch master cylinder push rod (1) to the clutch pedal pin (2).
8. Push the clutch master cylinder push rod (1 onto the clutch pedal pin (2) to secure.
9. Check for proper clutch pedal movement and operation.
10. Install the driver side instrument panel insulator. Refer to Instrument Panel Insulator
11. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
Hydraulic Clutch Hose/Pipe Replacement

Removal Procedure
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface
section.
Note: It is not necessary to drain the coolant or disconnect the coolant lines from the coolant
surge tank.
1. Remove the surge tank bolts and position the tank out of the way. Refer to Radiator Surge
Tank Replacement.
2. Remove the clutch hydraulic hose retaining clip from the clutch master cylinder.
Note: Install a cap or plug to the exposed hose and clutch master cylinder fittings in order to
prevent fluid loss and contamination.
3. Disconnect the clutch hydraulic hose from the clutch master cylinder.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the clutch hydraulic hose retaining clip (1) from the clutch slave cylinder.
6. Disconnect the clutch hydraulic hose (2) from the clutch slave cylinder. It is not necessary to
plug the lower hose end or slave cylinder fitting as they are equipped with check valves. Only
minimal fluid loss may be experienced.
7. Remove the clutch hydraulic hose retainer (1).

8. Remove the clutch hydraulic hose from the vehicle.
1. Install the clutch hydraulic hose to the vehicle.
2. Attach the clutch hydraulic hose retainer (1).
3. Install the clutch hydraulic hose retaining clip (1) to the clutch slave cylinder.
Note: Ensure the clutch hydraulic hose is routed in an upward direction above the clutch
slave cylinder with no sharp bends, kinks, or downward loops. Ensure the clutch hydraulic
hose does not come in contact with any sharp or potentially hot surfaces.
4. Install the clutch hydraulic hose (2) to the vehicle.

5. Align the clutch hydraulic hose locating tab with the notch in the slave cylinder hose fitting.
6. Push the clutch hydraulic hose into the clutch slave cylinder until a "click" is heard.
7. Tug gently on the clutch hydraulic hose to ensure proper retention to the clutch slave
cylinder.
8. Lower the vehicle.
9. Install the clutch hydraulic hose retaining clip to the clutch master cylinder.
10. Connect the clutch hydraulic hose to the clutch master cylinder.
11. Push the clutch hydraulic hose into the clutch master cylinder until a "click" is heard.
12. Tug gently on the clutch hydraulic hose to ensure proper retention to the clutch master
cylinder.
13. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.
14. Position the coolant surge tank in the proper location and install the surge tank bolts. Refer
to Radiator Surge Tank Replacement.
Hydraulic Clutch Bleeding

Special Tools
• J 35555 Metal Mityvac

• J 43485 Power Steering Bleeder Adapter
1. Verify that all the lines and fittings are dry and secure.
2. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign
substances enter the system.
3. Remove the reservoir cap.
4. Fill the reservoir to the proper level with the required fluid.
Some manual transmission equipped vehicles have a combined brake and clutch fluid
reservoir.
5. Attach the J 43485 to the J 35555 , or equivalent.
Note: Brake fluid will deteriorate the rubber on the J 43485 . Use a clean shop cloth to wipe
away the fluid after each use.
6. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases,
the adapter will fit into the reservoir opening.
7. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter.
8. Refill the reservoir to the proper level.
9. Repeat steps 6 and 7.
10. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be
seen in the reservoir or until the fluid level no longer drops.
Warning: The vehicle will move if started in gear before the Actuator Cylinder is refilled and
operational. Start the vehicle the first time in neutral to help prevent personal injury from
vehicle movement and see if the transmission will shift easily into gear.
11. Pump the clutch pedal until firm (to refill actuator cylinder).
12. Add additional fluid if needed.
13. Test drive the vehicle to ensure proper operation.
Clutch Pedal Position Switch Replacement
Callout Component Name

Preliminary Procedure
Disconnect the clutch pedal position switch electrical connector.

Clutch Pedal Position Switch Bolt

1
Tighten
2.5 N·m (22 lb in)
Clutch Pedal Position Switch
Warning: Replacement or reprogramming of the ECM, or replacement of the clutch

pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure
be performed. Failure to perform the CPPS learn procedure may result in personal
2
injury or damage to the vehicle or its components if the vehicle is in gear and the
starter motor is accidentally engaged.
Perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal
Position Sensor Learn.
Clutch Pilot Bearing Replacement

Tools Required
• J 43276 Clutch Pilot Bearing Remover

• J 38836 Pilot Bushing Installer/Clutch
Removal Procedure
1. Remove the clutch. Refer to Clutch Assembly Replacement .
Important: When using the J 43276, J 43276 always secure the J 43276-1 tool body using a
wrench. Do not allow the J 43276-1 tool to rotate. Failing to do so causes damage to the
J 43276-1 tool body.
2. Remove the clutch bearing using the J 43276 .

2.1. Install the J 43276-1 into the clutch pilot bearing .
2.2. Using a wrench, secure the J 43276-1.
2.3. Insert the J 43276-2 into the J 43276-1.
2.4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is
completely removed from the crankshaft.
2.5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1.
2.6. Remove the J 43276-1 from the tool body.
1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. The washer serves as a stop
against the crankshaft face and will assist in installing the bearing to the proper depth.
2. Install the new pilot bearing (2) onto the tool.
3. Install a new pilot bearing into the crankshaft using the J 38836 .
4. Inspect the clutch pilot bearing for proper installation. A properly installed clutch pilot bearing
will be installed until flush to the rear of the crankshaft.
5. Install the clutch. Refer to Clutch Assembly Replacement .
Clutch Assembly Replacement (CTS)

Removal Procedure
1. Remove the manual transmission. Refer to Transmission Replacement.

2. Remove the clutch pressure plate bolts.
3. Remove the clutch pressure plate and driven disc from the dowel pins on the flywheel.
Note: When the clutch driven plate requires replacement, the engine flywheel must also be
replaced along with the clutch pressure plate as an assembly.
1. The splined portion of the driven plate protrudes out of the plate more on one side than the
other. The side that protrudes out more is the transmission side. The arrow in the graphic
indicates the front of the vehicle, or flywheel side of the driven plate.
2. Install the clutch pressure plate and driven plate to the dowel pins on the flywheel.
3. Install the clutch pressure plate bolts finger tight.
4. Using a commercially available universal clutch alignment tool, align the clutch driven plate
to the clutch pilot bearing.
5. Tighten the clutch pressure plate bolts in the sequence shown, starting with the number one
and following in numerical order.
5.1. Tighten all the clutch pressure plate bolts in sequence and evenly to
30 N·m (22 lb ft).
5.2. Loosen bolts (1, 2, 3) 180 degrees. Re-torque bolts (1, 2, 3) in sequence and evenly
30 N·m (22 lb ft).
5.3. Loosen bolts (4, 5, 6) 180 degrees. Re-torque bolts (4, 5, 6) in sequence and evenly
30 N·m (22 lb ft).
6. Install the manual transmission. Refer to Transmission Replacement.
Clutch Assembly Replacement (CTS-V)

Special Tools
• DT-49267 Dual Clutch Alignment Tool

• J 42386-A Flywheel Holding Tool
Removal Procedure
Caution: Refer to Battery Disconnect Warning in the Preface section.
1. Disconnect the negative battery cable.

2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the driveline support assembly with the transaxle. Refer to Front Frame
Replacement.
4. Remove the bell housing bolts. The upper bolts can be accessed by lowering the engine
cradle approximately 25 mm (1 in) and tipping the engine back.
5. If reusing the pressure plate assembly, place a alignment mark on the pressure plate and
flyweel for proper alignment during installation.
Note: Do Not use air tools to remove the clutch pressure plate bolts.
6. Loosen the clutch pressure plate bolts using the following sequence:
6.1. Loosen bolts 1 and 2 one full turn, then stop.
6.4. Repeat steps 5.1 through 5.3 until all the bolts are loose.
7. Remove the clutch pressure plate bolts from the flywheel.
8. Remove the clutch pressure plate and the clutch driven plates.
1. Inspect the clutch pressure plates and the clutch driven plate for wear or damage. Repair or
replace as necessary.
2. Inspect the engine flywheel. Refer to Engine Flywheel Replacement.
3. Using the DT-49267 , align the two clutch driven plates.
Note: Do Not use air tools to install the clutch pressure plate bolts.
4. Install the clutch driven plate and clutch pressure plate to the engine flywheel with the clutch
alignment tool still installed in the clutch assembly.
5. Align the match marks on the pressure plate and flywheel, if reusing the pressure plate
assembly.
6. Install the clutch pressure plate bolts finger tight.
7. Install J 42386-A and bolts. Use one M10 1.5 X 25 mm and one M10 1.5 X 45 mm bolt for
proper tool operation.
Tighten the J 42386-A bolts to 50 N·m (37 lb ft).
8. Tighten the clutch pressure plate bolts using the following sequence:
8.1. Finger tighten bolts 1 and 2.
8.2. Using a socket wrench, turn bolts 1 and 2 360 degrees.
8.7. Return to bolts 1 and 2 and rotate 360 degrees.
8.10. Repeat Steps 7.7 through 7.9 until the clutch pressure plate is flat against the
flywheel
8.11. Remove the clutch alignment tool.
8.12. Torque the bolts to 70 N·m (52 lb ft). in the numbered sequence shown.
9. Install the bell housing bolts and tighten to 50 N·m (37 lb ft).
10. Install the driveline support assembly and the transaxle. Refer to Front Frame Replacement.
11. Lower the vehicle.
12. Connect the negative battery cable and tighten the cable fastener to 15 N·m (11 lb ft).
Clutch Concentric Actuator Cylinder Replacement

Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement.

2. Remove the concentric actuator cylinder quick connect bolt (5).
3. Remove the 3 concentric actuator cylinder bolts (1).
4. Remove the concentric actuator cylinder (2).
5. Remove the O-ring (3).
1. Install the O-ring (3).

2. Install the concentric actuator cylinder (2).
3. Install the 3 concentric actuator cylinder bolts (1) and the quick connect bolt (5).
• Tighten the 3 concentric actuator cylinder bolts to 20 N·m (15 lb ft).
• Tighten the quick connect bolt to 10 N·m (89 lb in).
4. Install the transmission. Refer to Transmission Replacement.
Clutch Pressure Plate Adjustment (Tremec 6-Speed)
1. Place the clutch pressure plate, flat surface down, on a press.

2. Compress the pressure plate diaphragm spring fingers until tension is released from the
stepped adjusting ring.
3. Hold 2 screwdrivers, or other suitable tools, and place them against 2 of the 3 stepped
adjusting ring tension spring stops (1), just ahead of the adjusting ring tension springs.
4. Using the screwdrivers, rotate the stepped adjusting ring counterclockwise, compressing the
tension springs, until the adjusting ring steps are fully adjusted out, then continue to hold in
position. © 2010 General Motors Corporation. All rights reserved.
5. Release the press pressure from the pressure plate diaphragm spring fingers.
6. Release the adjusting ring tension spring stops.
7. Remove the pressure plate from the press.

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Document ID: 1985049 Page 1 of 1

Fastener Tightening Specifications

© 2010 General Motors Corporation. All rights reserved.

Adhesives, Fluids, Lubricants, and Sealers

© 2010 General Motors Corporation. All rights reserved.

Clutch Pedal Replacement

© 2010 General Motors Corporation. All rights reserved.

5. Remove the clutch fluid reservoir (1) from the cowl.

8. Rotate the clutch master cylinder (2) clockwise 1/8 turn.

1. Install the clutch pedal assembly (1) to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

Warning: Replacement or reprogramming of the ECM, or replacement of the clutch pedal

Clutch Return Spring Replacement

Clutch Master Cylinder Replacement

© 2010 General Motors Corporation. All rights reserved.

4. Remove the clutch fluid reservoir (1) from the cowl.

7. Rotate the clutch master cylinder (2) clockwise 1/8 turn.

Hydraulic Clutch Hose/Pipe Replacement

© 2010 General Motors Corporation. All rights reserved.

7. Remove the clutch hydraulic hose retainer (1).

2. Attach the clutch hydraulic hose retainer (1).

4. Install the clutch hydraulic hose (2) to the vehicle.

Hydraulic Clutch Bleeding

• J 35555 Metal Mityvac

5. Attach the J 43485 to the J 35555 , or equivalent.

© 2010 General Motors Corporation. All rights reserved.

Clutch Pedal Position Switch Replacement

Callout Component Name

Disconnect the clutch pedal position switch electrical connector.

Caution: Refer to Fastener Caution in the Preface section.

Warning: Replacement or reprogramming of the ECM, or replacement of the clutch

Clutch Pilot Bearing Replacement

• J 43276 Clutch Pilot Bearing Remover

1. Remove the clutch. Refer to Clutch Assembly Replacement .

2. Remove the clutch bearing using the J 43276 .

Clutch Assembly Replacement (CTS)

1. Remove the manual transmission. Refer to Transmission Replacement.

© 2010 General Motors Corporation. All rights reserved.

Caution: Refer to Fastener Caution in the Preface section.

Clutch Assembly Replacement (CTS-V)

• DT-49267 Dual Clutch Alignment Tool

Caution: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable.

© 2010 General Motors Corporation. All rights reserved.

Caution: Refer to Fastener Caution in the Preface section.

Tighten the J 42386-A bolts to 50 N·m (37 lb ft).

Clutch Concentric Actuator Cylinder Replacement

1. Remove the transmission. Refer to Transmission Replacement.

© 2010 General Motors Corporation. All rights reserved.

1. Install the O-ring (3).

Caution: Refer to Fastener Caution in the Preface section.

Clutch Pressure Plate Adjustment (Tremec 6-Speed)

1. Place the clutch pressure plate, flat surface down, on a press.

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