Clutch: Service and Repair

REMOVAL
1. Remove the transmission.





2. Install the special tools.





3. To prevent warping, unscrew the pressure plate mounting bolts two turns at a time in a crisscross pattern, then remove the pressure plate.
4. Remove the release bearing from the pressure plate.





5. Remove the clutch disc and special tools.

Clutch disc Inspection
1. Inspect the lining of the clutch disc for signs of slippage or oil. Replace it if it is burned black or oil soaked.





2. Measure the clutch disc thickness.

Clutch Disc Thickness:
Standard (New): 8.2 - 8.9 mm (0.32 - 0.35 inch)
Service Limit: 6.2 mm (0.24 inch)

If the thickness is less than the service limit, replace the clutch disc.





3. Measure the depth from the lining surface to the rivets, on both sides.

Rivet Depth:
Standard (New): 1.2 mm (0.047 inch) min.
Service Limit: 0.2 mm (0.01 inch)

If the depth is less than the service limit, replace the clutch disc.

Pressure Plate Inspection
1. Inspect the pressure plate surface for wear, cracks, and burning.
2. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area.





3. Inspect for warpage using a straight edge and feeler gauge. Measure across the pressure plate at three points.

Standard (New): 0.03 mm (0.001 inch) max.
Service Limit: 0.15 mm (0.006 inch)

If the warpage exceeds the service limit, replace the pressure plate.

INSTALLATION
1. Install the ring gear holder.





2. Apply grease to the splines of the clutch disc, then install the clutch disc using the special tools as shown.
3. Install the release bearing on the pressure plate.








4. Install the pressure plate. Make sure the release bearing does not come off.





5. Torque the mounting bolts in a crisscross pattern as shown. Tighten them in several steps to prevent warping the diaphragm spring. Make sure the release bearing does not come off.
6. Remove the special tools.
7. Reinstall the transmission.