Clutch: Service and Repair
CLUTCH UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Clutch Cover and Clutch Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until the spring tension is released.
3. Remove the clutch cover and disc.
Pilot Bearing Removal Notch
NOTE: The pilot bearing does not need to be removed unless you are replacing it.
- Use the SSTs to remove the pilot bearing.
Flywheel Removal Note
1. Hold the flywheel by using the SST
2. Remove the bolts evenly and gradually in the pattern shown.
3. Remove the flywheel.
4. Inspect for oil leakage from the crankshaft rear oil seal. If there is any such leakage or if the oil seal is damaged, replace the crankshaft rear oil seal.
Flywheel Installation Note
1. Install the flywheel to the crankshaft.
2. Hand-tighten the flywheel installation bolts.
3. Install the SST to the flywheel.
4. Tighten the flywheel installation bolts in the pattern shown.
Tightening torque 97 - 102 Nm (9.8 - 10.5 kgf-m, 71 - 75 ft.lbs.)
Pilot Bearing Installation Note
- Install a new pilot bearing by using a suitable pipe.
Pipe outer diameter 35.0 mm (1.38 inch)
Bearing installation depth 0.0 - 0.4 mm (0.0 - 0.015 inch)
Clutch Disc Installation Note
- Hold the clutch disc in position by using the SSTs.
Clutch Cover Installation Note
1. Install the SSTs.
2. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque 18 - 26 Nm (1.8 - 2.7 kgf-m, 14 - 19 ft. lbs.)
CLUTCH COVER INSPECTION
1. Measure the wear of the diaphragm spring fingers.
Depth 0.5 mm (0.020 inch) maximum
2. Measure the flatness of the pressure plate surface by using a straightedge and a feeler gauge as shown in the image.
Maximum clearance 0.5 mm (0.020 inch)
NOTE: When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block.
3. Rotate the flywheel and check for misaligned diaphragm spring fingers.
Misalignment 0.6 mm (0.024 inch) maximum
4. Replace the clutch cover if not as specified.
CLUTCH DISC INSPECTION
1. Inspect the contact surface of the clutch disc for scoring, cracks, burning, and oil contamination.
2. Remove minor scoring or burning by using emery paper. Repair if scoring or burning is major. Replace if cracked or oil-soaked.
3. Inspect for loose facing rivets and dampers. Replace the clutch disc if either is loose.
4. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides. Replace the clutch disc if its thickness is less than minimum.
Thickness 0.3 mm (0.012 inch) minimum
5. Measure the clutch disc runout by using a dial indicator. Replace the clutch disc if runout is excessive.
Runout 0.7 mm (0.028 inch) maximum
CLUTCH RELEASE COLLAR INSPECTION
CAUTION: Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing.
1. Turn the collar while applying force in the axial direction.
2. If the collar sticks or has excessive resistance, replace it.
PILOT BEARING INSPECTION
1. Without removing the pilot bearing from the flywheel, turn the bearing while applying force in the axial direction.
2. If the bearing sticks or has excessive resistance, replace it.
FLYWHEEL INSPECTION
1. Inspect the contact surface for scoring, cracks, and burning.
2. Remove minor scoring or burning by using emery paper. Repair if scoring or burning is major. Replace if cracked.
3. Inspect the ring gear teeth for wear and damage. If necessary, replace the flywheel.
4. Install a dial indicator on the cylinder block '
5. Measure the flywheel runout by using a dial indicator. Replace the flywheel if runout is excessive.
Runout 0.2 mm (0.0079 inch) maximum