Clutch Makes Chatter/Rattling Noise and/or Will Not Release when Clutch Pedal is Fully Depressed (Replace Clutch Driven Plate (Disc) Assembly and Pressure Plate Assembly)

Some customers may comment on a chatter or rattling noise when the clutch pedal is fully depressed or that the clutch will not fully release when the clutch pedal is depressed.

One or both of these conditions may be caused by the automatic adjusting clutch being unnecessarily adjusted during the assembly process. If the clutch is incorrectly adjusted, the pressure plate release/apply springs (fingers) may contact the clutch driven plate (disc) dampening springs when the pedal is fully depressed resulting in chatter or a rattling noise. This condition may also cause the clutch to drag or not fully disengage the transmission when the clutch pedal is depressed.

Replace Clutch Driven Plate (Disc) Assembly and Pressure Plate Assembly. (Refer to the Service Procedure in this bulletin.)

1. With engine running at idle speed, fully depress the clutch pedal and note presence of chattering/rattling/grinding noise. If noise is present, turn off engine and proceed to step 2.
2. Remove transmission. (Refer to the "Transmission Replacement" section in the 2003 Saturn ION Transmission Service Manual.)
3. Loosen clutch cover (pressure plate) bolts alternately and evenly, one turn at a time until spring pressure is relieved and all bolts are removed.



4. Remove clutch cover (pressure plate) and clutch disc.



5. Assemble new clutch driven plate (disc) and clutch cover (pressure plate) to fly-wheel using Clutch Alignment Arbor Tool (J43482) to align disc to fly-wheel and assist in supporting cover.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricant or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install clutch cover (pressure plate) to flywheel bolts.




Important: Tighten clutch cover to flywheel bolts following the tightening sequence.

Tighten
Tighten the flywheel bolts to 24N·m(18 ft-lbs).

7. Tighten bolts alternately and evenly one turn at a time until cover mounting bosses contact the flywheel.
8. Remove Clutch Alignment Arbor Tool (J43482).

Important: Excessive amounts of lubricant on the input shaft splines may contaminate the clutch disc and cause clutch chatter.

9. Lubricate the inside diameter of the throwout bearing with Saturn P/N 21005995 (in Canada, P/N 10953532), or equivalent.
10. Install the transmission. (Refer to the "Transmission Replacement" section of the 2003 Saturn ION Transmission Service Manual.)
11. Bleed the hydraulic system. (Refer to the "Hydraulic Clutch Bleeding" section of the 2003 Saturn ION Transmission Service Manual.)
12. Verify that the chatter/rattling noise has been eliminated.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for K0800 - Disc (Driven Plate) and/or Clutch Cover (Pressure Plate)-Replace.