Clutch Disc: Service and Repair

Clutch Disc and Pressure Plate

Special Tool(s):

Material:

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 special tool, rotate the flywheel and check for spring ends that are higher or lower than the rest.
- The specification is 0.6 mm (0.02 inch) maximum.





3. Using the special tool, lock the flywheel to the engine.

4. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.

CAUTION: Loosen the bolts evenly to prevent pressure plate damage.





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

5. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.

Using a suitable commercial alcohol-based solvent, clean the clutch pressure plate.
6. Inspect the clutch pressure plate surface for bum marks, scores, flatness, ridges or cracks.
^ Maximum clearance for flatness check is 0.3 mm (0.012 inch).

7. CAUTION: 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.

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

Inspect the clutch disc for:
^ Oil or grease saturation.
^ Worn or loose facings.
^ Warpage or loose rivets at the hub.
^ Wear or rust on the splines.
8. Check the clutch disc runout.
9. If necessary, carry out 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 small amount of grease on clutch disc hub. Using the clutch disc aligner, position the clutch disc on the flywheel.





2. Position the clutch pressure plate on the flywheel and to the dowels. Install the clutch pressure plate bolts.
^ Tighten to 29 Nm (21 ft. lbs.) in a star pattern.
3. 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.
4. Install the clutch release bearing and the clutch release fork.
5. Install the transaxle.
^ Apply a small amount of grease to the transmission input shaft end and on the splines.