Clutch: Service and Repair

Clutch Assembly Replacement

Special Tools

* DT-49267 - Dual Clutch Alignment Tool

* J 42386-A - Flywheel Holding Tool

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement Transmission Replacement

2. If reusing the pressure plate assembly, place an alignment mark on the pressure plate and flywheel for proper alignment during installation.





Note:
Do Not use air tools to remove the clutch pressure plate bolts.

3. Loosen the clutch pressure plate bolts using the following sequence:

1. Loosen bolts 1 and 2 one full turn, then stop.

2. Loosen bolts 3 and 4 one full turn, then stop.

3. Loosen bolts 5 and 6 one full turn, then stop.

4. Repeat steps 5.1 through 5.3 until all the bolts are loose.

4. Remove the clutch pressure plate bolts from the flywheel.

5. Remove the clutch pressure plate and the clutch driven plates.

Installation Procedure





1. Inspect the clutch pressure plates and the clutch driven plate for wear or damage. Repair or replace as necessary.

2. Inspect the engine flywheel. Refer to Engine Flywheel Replacement Engine Flywheel Replacement.

3. Using the DT-49267 - tool, align the two clutch driven plates.





Note:

* Use NEW clutch pressure plate bolts in order to maintain proper torque. Apply red LOCTITE 242 to the threads to make certain the bolts do not come loose.

* Do Not use air tools to install the clutch pressure plate bolts.

4. Install the clutch driven plate and clutch pressure plate to the engine flywheel with the clutch alignment tool still installed in the clutch assembly.

5. If reusing the clutch pressure plate, align the previously created mark on the flywheel with the alignment mark on the pressure plate.

6. Install the NEW clutch pressure plate bolts finger tight.

Caution:
Refer to Fastener Caution Fastener Caution.

7. Install J 42386-A - tool and bolts. Use one M10 1.5 X 25 mm and one M10 1.5 X 45 mm bolt for proper tool operation.

Tighten the J 42386-A - tool bolts to 50 Nm (37 lb ft).





8. Tighten the clutch pressure plate bolts using the following sequence:

1. Finger tighten bolts 1 and 2.

2. Using a socket wrench, turn bolts 1 and 2 360 degrees.

3. Finger tighten bolts 3 and 4.

4. Using a socket wrench, turn bolts 3 and 4 360 degrees.

5. Finger tighten bolts 5 and 6.

6. Using a socket wrench, turn bolts 5 and 6 360 degrees.

7. Return to bolts 1 and 2 and rotate 360 degrees.

8. Return to bolts 3 and 4 and rotate 360 degrees.

9. Return to bolts 5 and 6 and rotate 360 degrees.

10. Repeat steps 7.7-7.9 until the clutch pressure plate is flat against the flywheel

11. Remove the clutch alignment tool.

12. Torque the bolts to 70 Nm (52 lb ft) in the numbered sequence shown.

9. Install the transmission. Refer to Transmission Replacement Transmission Replacement.