Removal and Replacement

Clutch Disc and Pressure Plate

















Removal

Clutch disc and clutch pressure plate

1. Remove the transaxle. For additional information, refer to Manual Transmission/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 (0.023 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. For additional information, refer to Manual Transmission/Transaxle &/or Clutch, M/T.
- Maximum clearance for flatness check is 0.3 mm (0.011 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. For additional information, refer to Engine or Manual Transmission/Transaxle.

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. For additional information, refer to Clutch Disc Check in Manual Transmission/Transaxle &/or Clutch, M/T.

9. If necessary, conduct a Flywheel Runout Check. For additional information, refer to Manual Transmission/Transaxle &/or Clutch, M/T.

Clutch release bearing and clutch release fork

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

Clutch release bearing and clutch release fork

1. Install the clutch release fork.





2. Check for roughness or sticking. If the bearing feels rough, sticks or has excessive resistance, install a new bearing. Slide the release bearing on the guide tube.

3. Install the clutch release bearing.





Clutch disc and clutch pressure plate

4. 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.

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












6. 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).





7. 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.

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

Install the transaxle.