Removal and Replacement

Clutch Disc and Pressure Plate

















Removal

1. Remove the transaxle.

2. Inspect the clutch pressure plate.
- Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.

- Using the Dial Indicator Gauge with Holding Fixture, rotate the flywheel and check for spring ends that are higher or lower than the rest.
- The specification is 0.6 mm (0.02 in) maximum.





3. Using the Flywheel Holding Tool, lock the flywheel to the engine.





4. NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.

Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.





5. NOTE: Do not immerse the clutch pressure plate in solvent.

Using a suitable cleaning solution, clean the clutch pressure plate.

6. Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks.
- Maximum clearance for flatness check is 0.3 mm (0.012 in).

7. NOTICE: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal or transmission input shaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation.

NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.

Inspect the clutch disc for the following:
- Oil or grease saturation

- Worn or loose facings

- Warpage or loose rivets at the hub

- Wear or rust on the splines

- Install a new clutch disc if any of these conditions are present.

8. Check the clutch disc runout.

9. If necessary, conduct a Flywheel Runout Check.

10. Remove the clutch release bearing.





11. Inspect the clutch release bearing for wear or damage.
- Rotate the bearing while applying pressure in the axial direction. If the bearing feels rough, sticks or has excessive resistance, install a new bearing.





12. Inspect the release bearing guide tube for wear or damage.
- Slide the release bearing on the guide tube. Check for roughness or sticking.

13. Remove the clutch release fork. Inspect the fork for wear or damage.

Installation

1. Apply a very small amount of grease in the clutch disc hub. Wipe off excess grease to avoid contaminating the clutch disc and affecting clutch function.

2. Using a suitable clutch disc aligner, position the clutch disc on the flywheel.









3. Position the clutch pressure plate on the flywheel and to the dowels. Install the 6 clutch pressure plate bolts.
- Tighten the bolts one turn at a time in a star pattern. Tighten to 29 Nm (21 lb-ft).





4. Apply a small amount of grease to:
- the clutch release fork fingers.

- the clutch release fork spring.

- the guide tube.

- the clutch slave cylinder end that contacts the release fork.

5. Install the clutch release bearing and the clutch release fork.

6. NOTE: Apply a very small amount of grease to the transmission input shaft end and on the splines.

Install the transaxle.