Complete procedure for replacing the pressure plate and clutch assembly on a 1966 Chevrolet Corvette 327ci V8, requiring transmission removal for access.

Warnings

Tools required

Parts

• Pressure plate assembly × 1 — Use OEM specification
• Clutch disc × 1 — Use OEM specification
• Pilot bearing or bushing × 1 — Use OEM specification
• Throwout bearing (release bearing) × 1 — Use OEM specification
• Transmission input shaft seal × 1 — Use OEM specification
• Transmission rear seal × 1 — Use OEM specification
• Bell housing gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Disconnect negative battery cable
3. Allow exhaust system to cool completely if vehicle was recently driven
4. Remove driver side seat cushion for interior transmission tunnel access (if removing shifter from above)
5. Mark driveshaft and rear axle yoke alignment for reinstallation reference
6. Gather all tools and parts before beginning procedure

Procedure

1. 1

   Raise and support vehicle
   Raise the vehicle using a floor jack at the front crossmember and rear differential. Position jack stands under the frame rails at approved jacking points. Ensure vehicle is stable and level. Remove rear wheels if additional clearance is needed for access.
2. 2

   Disconnect driveshaft
   Remove the 4 U-bolts securing the driveshaft to the rear axle yoke. Support the driveshaft and slide it rearward out of the transmission. Insert a plug or plastic bag into the transmission output to prevent fluid loss. Set driveshaft aside in a safe location maintaining alignment marks.
3. 3

   Disconnect exhaust system
   Remove the exhaust pipe flange bolts at the exhaust manifolds (2 bolts per side). Support the exhaust system and lower or move aside as needed for transmission clearance. On side-pipe equipped Corvettes, additional exhaust disconnection may be required.
4. 4

   Remove transmission crossmember
   Support the transmission with a transmission jack positioned under the pan. Remove the 2 transmission mount bolts securing the transmission to the crossmember. Remove the 4 bolts securing the crossmember to the frame and remove the crossmember.
5. 5

   Disconnect shifter and linkage
   From inside the vehicle, remove the shift lever boot and remove the 4 bolts securing the shifter assembly to the transmission. Lift shifter out. Alternatively, disconnect shifter linkage from underneath if equipped. Disconnect backup light switch wiring connector on transmission.
6. 6

   Disconnect clutch linkage
   Disconnect the clutch fork return spring. Remove the clutch fork pushrod from the clutch cross shaft. On early '66 models, disconnect the clutch linkage at the bell housing or frame bracket as equipped. Ensure all clutch linkage is free from the bell housing.
7. 7

   Disconnect speedometer cable
   Locate the speedometer cable at the right side of the transmission tail housing. Unscrew the speedometer cable ferrule and carefully pull the cable from the transmission housing.
8. 8

   Remove transmission and bell housing
   Remove the 4 bell housing to engine block bolts. Carefully slide the transmission and bell housing assembly rearward, keeping it level to avoid binding on the clutch disc or input shaft. The assembly is heavy; use the transmission jack and have an assistant guide it. Once the input shaft clears the clutch, lower the transmission and remove from under the vehicle.
9. 9

   Inspect clutch assembly and flywheel
   Examine the exposed clutch disc, pressure plate, and flywheel. Check for oil contamination, worn friction material, cracking, heat discoloration, or glazing. Measure flywheel runout if tools are available (should not exceed 0.005 inches). Note condition for determining whether flywheel resurfacing is required.
10. 10

    Remove pressure plate assembly
    Insert the flywheel holding tool to prevent crankshaft rotation. Mark the pressure plate orientation to the flywheel for reference. Gradually loosen the 6 pressure plate bolts in a crisscross pattern, approximately 1-2 turns each in sequence, to prevent distortion. Once all bolts are loose, remove them completely and carefully remove the pressure plate and clutch disc together.
    ⚠Do not remove pressure plate bolts in a circular pattern or all at once. Uneven pressure release can warp the pressure plate or flywheel.
11. 11

    Remove and replace pilot bearing
    Inspect the pilot bearing or bushing in the center of the crankshaft. Using a pilot bearing puller or slide hammer, remove the old bearing. Clean the crankshaft bore thoroughly. Drive or press the new pilot bearing into the crankshaft bore until it is flush or slightly recessed (approximately 0.030-0.050 inches). Lubricate the bearing lightly with high-temperature grease.
12. 12

    Clean and prepare flywheel surface
    Use a wire brush and brake cleaner to thoroughly clean the flywheel friction surface. Remove any glaze with fine emery cloth if flywheel is being reused. Ensure the surface is completely free of oil, grease, or contaminants. Clean the pressure plate mounting area and bolt holes.
13. 13

    Install new clutch disc
    Position the new clutch disc against the flywheel with the hub side (stamped marking 'Flywheel Side' or with longer hub projection) facing away from the flywheel toward the transmission. Insert the clutch alignment tool through the disc and into the pilot bearing to hold the disc centered.
14. 14

    Install new pressure plate
    Position the new pressure plate over the clutch disc, aligning the dowel pins if equipped or using the reference marks made earlier. Start all 6 pressure plate bolts by hand. Tighten the bolts gradually in a crisscross pattern, bringing the pressure plate down evenly. Final tighten bolts to proper specification in three stages using the crisscross sequence.
15. 15

    Install throwout bearing and inspect clutch fork
    Separate the bell housing from the transmission if not already done. Remove the old throwout bearing from the clutch fork. Inspect the clutch fork for wear, cracks, or damage at the pivot point and bearing contact area. Install the new throwout bearing onto the clutch fork, ensuring it snaps or clips securely into place. Apply a small amount of high-temperature grease to the fork pivot ball and bearing contact points.
16. 16

    Reinstall transmission and bell housing
    Apply a thin bead of RTV sealant or install a new bell housing gasket to the bell housing mating surface. Position the transmission and bell housing assembly on the transmission jack. Carefully guide the transmission input shaft through the clutch disc and into the pilot bearing, keeping the assembly level. The clutch alignment tool will guide the shaft; remove the tool once the input shaft is partially engaged. Push the transmission forward until the bell housing seats against the engine block. Install the 4 bell housing bolts and tighten securely.
    ⚠Do not force the transmission forward. If resistance is felt, the input shaft splines may not be aligned with the clutch disc. Rotate the transmission output shaft slightly while applying gentle forward pressure.
17. 17

    Reinstall transmission crossmember and mount
    Raise the transmission slightly with the jack to align with the crossmember position. Install the crossmember to the frame with the 4 bolts and tighten securely. Install the 2 transmission mount bolts and tighten. Remove the transmission jack.
18. 18

    Reconnect all components
    Reconnect the speedometer cable to the transmission. Reconnect the backup light switch wiring. Reinstall the shifter assembly with the 4 bolts from inside the vehicle, or reconnect external shifter linkage. Reconnect the clutch fork pushrod and clutch fork return spring. Adjust clutch linkage as required for proper pedal height and free play.
19. 19

    Reinstall driveshaft and exhaust
    Remove the plug from the transmission output housing. Align the driveshaft with the reference marks made during disassembly. Slide the driveshaft forward into the transmission and connect to the rear axle yoke. Install the 4 U-bolts and tighten securely. Reconnect the exhaust system at the manifold flanges with new gaskets if needed.
20. 20

    Final inspection and lower vehicle
    Verify all bolts are tightened and all connections are secure. Check for any tools or parts left in the work area. Reinstall rear wheels if removed. Carefully lower the vehicle from jack stands to the ground. Reconnect the negative battery cable.

Reassembly

1. Ensure clutch pedal free play is adjusted to 1 to 1.5 inches measured at the pedal pad before road test
2. Check transmission fluid level and top off if needed after driveshaft reconnection
3. Torque all critical fasteners to specification when torque values become available for this vehicle

Verification

• Start the engine with the clutch pedal depressed and transmission in neutral
• Verify the clutch disengages smoothly without grinding when shifting into first gear
• Test clutch engagement by slowly releasing the pedal; engagement should be smooth and progressive without chatter or slipping
• Perform a road test through all gears, verifying smooth shifts and no clutch slip under acceleration
• Check for any fluid leaks around the bell housing, transmission, or driveshaft connections
• Verify proper clutch pedal feel and return with no unusual noises from the bell housing area

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