Clutch Assembly Replacement (Without DT-6263)
Clutch Assembly Replacement (Without DT-6263)
Special Tools
DT-50194 - Clutch Disc Alignment Tool or equivalent.
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Removal Procedure
1. Remove the transmission. Refer to Transmission Replacement Transmission Replacement.
Note:
Discard the bolts.
2. Remove the 6 clutch pressure plate bolts (1).
3. Remove the clutch pressure plate (2) and driven plate (1).
Note:
Clutch pressure plate and driven plates contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check clutch driven plate for damage and friction rust in the hub profile and replace if necessary. Do not clean clutch pressure plate and driven plate with a high pressure cleaner or component washing machine.
4. Inspect the clutch pressure plate and driven plate (1) and replace if necessary. Inspect for the following conditions:
* Excessive wear
* Burned friction surface
* Oil on friction surface
* Damaged spline hub
* Damaged springs
Note:
The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in)(arrows).
5. Inspect projection of lining at the clutch lining rivets.
6. Slide the clutch driven plate onto the transmission input shaft and check for easy movement.
Installation Procedure
1. Clean 6 threads in flywheel for fastening clutch pressure plate.
Note:
Clutch driven plate must be installed so that the lettering on the hub faces the transmission.
2. Install the driven plate (1) and clutch pressure plate (2).
3. Hand start 6 NEW clutch pressure plate bolts, leaving the clutch pressure plate lose enough to reposition for alignment
4. Using DT-50194 - Clutch Disc Alignment Tool or equivalent, align the clutch driven plate to the clutch pilot bearing.
Caution:
Refer to Fastener Caution Fastener Caution.
5. Tighten the clutch pressure plate bolts in sequence to 28Nm (21 lb ft).
6. Install the transmission. Refer to Transmission Replacement Transmission Replacement.