Measuring Clutch Pack Height

WARNING: This page is about a different car, the 2008 GMC Yukon XL, 2008 GMC Yukon, 2008 Chevrolet Tahoe, 2008 Chevrolet Suburban, and 2008 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Measuring Clutch Pack Height

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
Preliminary Procedure The DT-48213 applies a predetermined amount of pressure to the clutch pack in order to properly measure the clutch pack height. See Special Tools . Do not use any other method than what is outlined below. Micrometers or depth gages may also be used in conjunction with the DT-48213 to measure the clutch pack height. See Special Tools . Two variations are available to measure clutch pack height, outside measurement or inside measurement. Either variation will determine the correct height.
1	Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plates (Qty: 8) Tip: Install the friction and steel clutch plates into the DT-48213 , alternating until 8 friction plates and 7 steel plates are installed. See Special Tools . Special Tools: DT-48213 Clutch Pack Height Gage. See Special Tools .
2	Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plates (Qty: 7) Procedure 1 - Outside Measurement: Tighten the DT-48213 until the upper portion of the tool contacts the lower portion of the tool. See Special Tools . The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates. Using an outside caliper, measure the total combined height of the clutch pack and the DT-48213 , dimension a. See Special Tools . Subtract the thickness of both the upper and lower portion of the DT-48213 , 14 mm (0. See Special Tools .551 in), and record the results. Repeat the process in 2 additional locations, 120 degrees from each other. The average of the 3 measurements is the clutch pack height. Procedure 2 - Inside Measurement: Tighten the DT-48213 until the upper portion of the tool contacts the lower portion of the tool. See Special Tools . The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates. Using an inside caliper, measure the height of the clutch pack, dimension b, and record the results. Repeat the process in 2 additional locations, 120 degrees from each other. The average of the 3 measurements is the clutch pack height. Tip: Install the friction and steel clutch plates into the DT-48213 , alternating until 8 friction plates and 7 steel plates are installed. See Special Tools . Special Tools: DT-48213 Clutch Pack Height Gage. See Special Tools .

Callout

Component Name

Preliminary Procedure

The DT-48213 applies a predetermined amount of pressure to the clutch pack in order to properly measure the clutch pack height. See Special Tools . Do not use any other method than what is outlined below.
Micrometers or depth gages may also be used in conjunction with the DT-48213 to measure the clutch pack height. See Special Tools .
Two variations are available to measure clutch pack height, outside measurement or inside measurement. Either variation will determine the correct height.

Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plates (Qty: 8)
Tip: Install the friction and steel clutch plates into the DT-48213 , alternating until 8 friction plates and 7 steel plates are installed. See Special Tools .
Special Tools:
DT-48213 Clutch Pack Height Gage. See Special Tools .

Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plates (Qty: 7)

Procedure 1 - Outside Measurement:

Tighten the DT-48213 until the upper portion of the tool contacts the lower portion of the tool. See Special Tools . The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
Using an outside caliper, measure the total combined height of the clutch pack and the DT-48213 , dimension a. See Special Tools . Subtract the thickness of both the upper and lower portion of the DT-48213 , 14 mm (0. See Special Tools .551 in), and record the results.
Repeat the process in 2 additional locations, 120 degrees from each other.
The average of the 3 measurements is the clutch pack height.

Procedure 2 - Inside Measurement:

Tighten the DT-48213 until the upper portion of the tool contacts the lower portion of the tool. See Special Tools . The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
Using an inside caliper, measure the height of the clutch pack, dimension b, and record the results.
Repeat the process in 2 additional locations, 120 degrees from each other.
The average of the 3 measurements is the clutch pack height.

Tip: Install the friction and steel clutch plates into the DT-48213 , alternating until 8 friction plates and 7 steel plates are installed. See Special Tools .
Special Tools:
DT-48213 Clutch Pack Height Gage. See Special Tools .