Unit Overhaul

CLUTCH ASSEMBLY (HEC, B.W.T5R/MUA)





CLUTCH ASSEMBLY (HEC, B.W.T5R) AND ASSOCIATED PARTS





CLUTCH ASSEMBLY (HEC, MUA) AND ASSOCIATED PARTS

REMOVAL
1. Remove transmission assembly.





2. Use the clutch pilot aligner (7) J-33169 (B.W.)/J-42877 (MUA) to prevent the driven plate assembly from falling free.
3. Mark the flywheel, clutch cover and pressure plate (2) lug for alignment when installing.





4. Loosen the clutch cover bolts in the numerical order shown in the illustration.
5. Remove pressure plate assembly (2) and driven plate assembly (3).
6. Remove release bearing (4).

NOTE: The release bearing is permanently packed with lubricant and should not be soaked in cleaning solvent, as this will dissolve the lubricant.

7. Remove shift fork.





- Do not remove crank shaft bearing (6) except for replacement. Remove the crank shaft bearing (6) using remover J-5822 and sliding hammer J-23907.

INSPECTION AND REPAIR
Make necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during inspection.

Pressure Plate Assembly
Visually inspect the pressure plate friction surface for excessive wear and heat cracks. If excessive wear or deep heat cracks are present, the pressure plate must be replaced.


Pressure Plate Width
Use a vernier caliper to measure the pressure plate width.





Standard: 10 mm (0.39 inch)

Pressure Plate Warpage





Use a straight edge and a feeler gauge to measure the pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the pressure plate must be replaced.

Limit: 0.3 mm (0.012 inch)

Clutch Cover





Visually inspect the entire clutch cover for excessive wear, cracking, and other damage. The clutch cover must be replaced if any of these conditions are present.

Clutch Set Force
1. Invert the pressure plate assembly.





2. Place a new driven plate over the pressure plate. A metal sheet with thickness of 8.O mm (0.315 inch) may be used in place of the driven plate.
3. Compress the pressure plate assembly until the distance becomes 4 mm (0.157 inch).
4. Note the pressure gauge reading.

Standard: 5488 N (1235 lbs.)


Diaphragm Spring Finger Height
1. Place a 8.0 mm (0.315 inch) spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring. There are two ways to do this:
a. Use a bench press to press down on the assembly from the top.
b. Tighten the fixing bolts.





3. Measure the spring finger height from base to spring tip. If the measured value exceeds the specified limit, the pressure plate assembly must be replaced.

Spring Finger Height
Standard: 37.5 mm - 39.5 mm (1.48 inch - 1.56 inch)

Shift fork
1. Visually inspect the surfaces of the shift fork making contact with the shift block.
2. Remove any minor stepping or abrasion from the shift block with an oil stone.
3. Apply molybdenum disulfide type grease to the areas as shown in the figure.





MUA





B.W.T5R


Driven Plate Assembly
1. Visually inspect the torsion spring for looseness, breakage, and weakening. If any of these conditions are discovered, the driven plate assembly must be replaced.





2. Visually inspect the facing surfaces for cracking and excessive scorching. Visually inspect the facing surfaces for the presence of oil or grease. If any of these conditions are discovered, the facing must be cleaned or replaced.
3. Check that the driven plate moves smoothly on the transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed with an oil stone.

Driven Plate Warpage
1. Insert the clutch pilot aligner J-33169 (B.W.) J-42877 (MUA) into the driven plate splined hub. The clutch pilot aligner must be held perfectly horizontal.





2. Set a dial indicator to the driven plate outside circumference.
3. Slowly turn the driven plate. Read the dial indicator as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly must be replaced.

Driven Plate Warpage
Standard: 0.7 mm (0.028 inch)
Limit: 1.0 mm (0.039 inch)

Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft spline.
3. Set a surface gauge to the driven plate outside circumference.





4. Slowly turn the driven plate counterclockwise. Measure the spline rotation play as you turn the driven plate.

Driven Plate Splined Hub Spline Wear
Standard: 0.5 mm (0.020 inch)
Limit: 1.0 mm (0.039 inch)

Rivet Head Depression





Use a depth gauge or a straight edge with steel rule to measure the rivet head depression (1) from the facing surface (2). Be sure to measure the rivet head depression on both sides of the driven plate. If the measured value is less than the specified limit, the facing must be replaced.

Rivet Head Depression
Standard: MIN 1.3 mm (0.051 inch)
Limit: 0.2 mm (0.008 inch)

Pressure Plate Assembly





Check the cover for cracks and distortion, and the diaphragm spring for heat distortion, loosened rivets. Check the diaphragm spring for wear.

INSTALLATION
1. Clean and lubricate with grease.
2. Use installer J-1 522 to install crankshaft bearing (6).





HEC

3. Apply molybdenum disulfide type grease to the areas as shown in the figure and install shift fork (5).





MUA





B.W.T5R





4. Pack the inside recess (A) and coat the outside groove (B) of the release bearing with grease as shown in the figure.





5. Install driven plate assembly by using aligner J-33169 (B.W.)/J-42877 (MUA).





6. Tighten the bolts holding the pressure plate assembly (2) in the order shown in the figure.

Torque: 18 Nm (13 ft. lbs.)

7. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove it.

8. Install transmission assembly (1) to the engine.

SHIFT FORK LUBRICATION





B.W. T5R

1. Remove the plug from the clutch housing.
2. Lubricate the shift fork through a lubrication hole of ball stud with grease using a grease gun.
3. Install the plug to the clutch housing.