Unit Overhaul

CLUTCH ASSEMBLY (V6, MUA) AND ASSOCIATED PARTS

REMOVAL

1. Remove transmission assembly (1).





2. Use the pilot aligner J24547 to prevent the driven plate assembly (3) from falling free.
3. Mark the flywheel, clutch cover and pressure plate lug for alignment when installing.





4. Remove the release bearing (4) from the transmission case.





5. Remove the snap pin. Remove the shift fork pin and shift fork from the fulcrum bridge.





6. Remove the fulcrum bridge bolts. Remove the fulcrum bridge (6) from the transmission case.
- Do not remove crankshaft bearing (7) except for replacement.





- Use the remover J-5822 and sliding hammer J-23907 to remove the crankshaft bearing.

INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage, or any other abnormal condition are found through inspection.

Pressure Plate Assembly





- Visually check 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 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 check 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 8.0 mm (0.315 inch) may be used in place of the driven plate.
3. Compress the pressure plate assembly until the distance becomes 12 mm (0.472 inch).
4. Note the pressure gauge reading. If the measured value is less than the specified limit, the pressure plate assembly must be replaced.

Clutch Set Force
Standard: 7208 N (1621 lbs.)
Limit: 6669 N (1499 lbs.)

Diaphragm Spring Finger Height
1. Place a new driven plate or 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.

NOTE: Preload on diaphragm spring finger must be 4998 N (11-22 lbs.) in direction of release, when clutch cover assembly is bolted to the flywheel.





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

Standard: 49.9 - 51.9 mm (1.965 - 2.043 inch)

Driven Plate Assembly





- Visually check the torsion spring for looseness, breakage, and weakening. If any of these conditions are discovered, the driven plate assembly must be replaced.
- Visually check 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.
- 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-24547 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. If the measured value exceeds the specified limit, the driven plate assembly must be replaced.

Driven Plate Warpage
Standard: 0.5 mm (0.020inch)
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 driven plate assembly must be replaced.





Rivet Head Depression


Release Bearing





- Visually check the release bearing for excessive play, noise and breakage. If any of these conditions are discovered, the release bearing must be replaced.





- When replacing the release bearing (4), replace both the wedge collar (10) and wire ring (11) at the same time.

Wedge Collar (10)





- Visually check the surfaces of the wedge collar making contact with the release bearing for excessive wear and damage.
- Replace exhibiting excessive wear or damage.

Shift Fork





- Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage.
- Remove any minor stepping or abrasion from shift fork with an oil stone. Replace exhibiting excessive wear or damage.


INSTALLATION
1. Clean and lubricate with grease.





2. Use the installer J-26516-A and driver handle J-8092 to install the crankshaft bearing (7).





3. Install the fulcrum bridge (6) to the transmission case. Tighten three fulcrum bridge bolts to the specified torque.

Torque: 38 Nm (28 Ft. lbs.)





4. Apply molybdenum disulfide type grease to the pin hole inner circumferences and thrust surfaces. Attach the shift fork (5) to the fulcrum bridge (6) and insert the pin from below of the fulcrum bridge. Install the washer and snap pin.





5. Apply molybdenum disulfide type grease to the areas shown in the figure.
Install the release bearing (4) in the proper direction.





NOTE: Ensure release bearing is properly positioned during installation, as shown in the figure.





6. Use the pilot aligner -24547 to install the driven plate assembly (3).





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

Torque: 18 Nm (13 Ft. lbs.)

8. Remove the aligner.

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

9. Install transmission assembly to the engine.