Complete removal and replacement of the clutch kit (disc, pressure plate, and throw-out bearing) on a 1966 Corvette with 327ci V8, requiring transmission removal.

Warnings

Tools required

Parts

• Clutch kit (disc, pressure plate, throw-out bearing) × 1 — Use OEM specification or performance equivalent for 327 V8
• Pilot bearing × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Clutch fork boot × 1 — Use OEM specification
• Transmission fluid (Dexron III ATF) × 1 — Use specified fluid type

Fluids

• Dexron III ATF — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Chock rear wheels securely.
3. Disconnect negative battery cable.
4. Allow engine and exhaust system to cool completely if recently operated.
5. Raise front of vehicle and support securely on jack stands under frame rails.
6. Remove both rear wheels and support rear of vehicle on jack stands under rear axle.
7. Place transmission jack under transmission for initial support.

Procedure

1. 1

   Disconnect driveshaft
   Mark the relationship between the driveshaft and rear differential pinion flange for proper reassembly. Remove the 4 U-joint strap bolts at the rear differential. Lower the rear of the driveshaft and slide it rearward out of the transmission. Place a plastic bag or cap over the transmission extension housing to prevent fluid loss.
2. 2

   Disconnect clutch linkage
   Working from underneath, disconnect the clutch fork return spring. Remove the clutch cross-shaft and swivel at the clutch fork. Disconnect the clutch pushrod from the clutch fork by removing the clevis pin.
3. 3

   Disconnect transmission electrical connections
   Disconnect the backup light switch wire connector and the speedometer cable at the transmission. Tag any other electrical connections for reference during reassembly.
4. 4

   Remove transmission mount and crossmember
   Support the transmission securely with a transmission jack. Remove the 2 transmission mount-to-crossmember bolts. Remove the 4 crossmember-to-frame bolts and lower the crossmember away from the vehicle.
5. 5

   Remove transmission-to-bellhousing bolts
   Remove the 4 transmission-to-bellhousing bolts. Carefully slide the transmission rearward on the transmission jack, ensuring the input shaft clears the clutch disc and pilot bearing. Lower the transmission from the vehicle. Note the position of any shims between the transmission and bellhousing.
6. 6

   Remove bellhousing inspection cover
   Remove the lower bellhousing inspection cover by removing the 4 bolts securing it. This provides access to the clutch assembly and flywheel.
7. 7

   Mark and remove pressure plate
   Use a punch or paint marker to mark the pressure plate position relative to the flywheel for balanced reassembly. Install all 6 pressure plate-to-flywheel bolts loosely to prevent warping, then loosen them gradually in a crisscross pattern, 2-3 turns at a time. Remove all bolts and carefully remove the pressure plate and clutch disc assembly.
8. 8

   Inspect flywheel and remove pilot bearing
   Inspect the flywheel surface for heat checking, cracks, or glazing. Minor glazing can be removed with emery cloth, but severe damage requires flywheel resurfacing or replacement. Use a pilot bearing puller or slide hammer with internal puller attachment to remove the pilot bearing from the center of the crankshaft.
9. 9

   Clean and prepare mating surfaces
   Clean the flywheel surface thoroughly with brake cleaner and a shop rag. Ensure no oil or grease remains on the friction surface. Wire brush the pressure plate mounting bolt threads in the flywheel. Inspect the clutch fork and pivot ball for wear.
10. 10

    Install new pilot bearing
    Lightly lubricate the outer diameter of the new pilot bearing with clean engine oil. Drive or press the new pilot bearing into the crankshaft until it is seated flush with the crankshaft face. Pack the bearing lightly with high-temperature wheel bearing grease.
11. 11

    Install clutch disc and pressure plate
    Position the clutch disc against the flywheel with the longer hub side (damper springs) facing the transmission. Insert the clutch alignment tool (1-1/16" 10-spline arbor) through the clutch disc and into the pilot bearing to center the disc. Position the pressure plate over the clutch disc, aligning the marks made during disassembly. Install all 6 pressure plate-to-flywheel bolts finger-tight. Tighten the bolts gradually in a crisscross pattern to ensure even pressure plate seating. Torque the bolts incrementally in three passes to final specification (typically 30-35 ft-lbs for this application). Remove the alignment tool only after all bolts are fully torqued.
12. 12

    Install new throw-out bearing and clutch fork
    Slide the new throw-out bearing onto the transmission input shaft bearing retainer. Apply a small amount of high-temperature grease to the clutch fork pivot ball and the fork ends where they contact the throw-out bearing. Install the clutch fork and secure it to the pivot ball. Install a new clutch fork boot to seal the bellhousing.
13. 13

    Reinstall transmission
    Apply a light coat of high-temperature grease to the transmission input shaft splines (avoid excess that could contaminate the clutch disc). Position the transmission on the transmission jack and carefully align the input shaft with the clutch disc splines using the alignment tool as a guide. Slide the transmission forward, ensuring the input shaft engages smoothly into the pilot bearing. If resistance is felt, do not force; rotate the transmission output shaft slightly to align splines. Install the 4 transmission-to-bellhousing bolts and tighten evenly. Reinstall any shims that were present during disassembly.
14. 14

    Reinstall crossmember and transmission mount
    Raise the transmission into position and install the crossmember with the 4 frame bolts. Install the 2 transmission mount-to-crossmember bolts and tighten all fasteners securely. Remove the transmission jack.
15. 15

    Reconnect all components
    Reconnect the speedometer cable and backup light switch. Reconnect the clutch pushrod to the clutch fork with the clevis pin. Reconnect the clutch cross-shaft and swivel, and install the clutch fork return spring. Align the marks on the driveshaft and pinion flange, then install the 4 U-joint strap bolts and tighten securely. Reinstall the bellhousing inspection cover. Check transmission fluid level and top off with SAE 80W-90 GL-4 gear oil as needed (approximately 2 pints if drained).

Reassembly

1. Reinstall rear wheels and torque lug nuts to specification.
2. Lower vehicle from jack stands.
3. Reconnect negative battery cable.
4. Adjust clutch pedal free play according to factory specification (typically 1-1.5 inches at pedal pad).

Verification

• Start engine and verify clutch pedal operates smoothly without binding or unusual noise.
• With engine running, depress clutch pedal fully and shift through all gears to verify smooth engagement.
• Test drive vehicle in a safe area, checking for smooth clutch engagement without slippage, chatter, or grabbing.
• Verify no fluid leaks from transmission or clutch hydraulic components.
• Recheck clutch pedal free play after initial test drive and adjust if necessary.
• Listen for abnormal noises from clutch or transmission during operation.

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