Clutch: Service and Repair

Clutch Release Mechanism

REMOVAL AND INSTALLATION





- Remove release bearing by pulling bearing retainers outward.

- Align spring pin with cavity of clutch housing and tap out spring pin.

- To install, reverse removal procedure.

INSPECTION





Check the following items, and replace if necessary.
- Release bearing, to see that it rolls freely and is free from noise, cracks, pitting or wear

- Release sleeve and withdrawal lever rubbing surface, for wear, rust or damage

LUBRICATION
- Apply recommended grease to contact surface and rubbing surface.

- Too much lubricant may damage clutch disc facing.





Clutch Disc

INSPECTION





Check the following items, and replace if necessary.
- Clutch disc, for burns, discoloration, oil or grease leakage

Clutch disc, for wear of facing.

Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)





- Clutch disc, for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc):

MODEL 190 0.8 mm (0.031 in)
MODEL 215 0.9 mm (0.035 in)

Runout limit:
1.0 mm (0.039 in)

Distance of runout check point (from hub center):
MODEL 190 90 mm (3.54 in)
MODEL 215 102.5 mm (4.04 in)

INSTALLATION
- Apply recommended grease to contact surface of splines.

Note: Too much lubricant may damage clutch disc facing.

Clutch Cover and Flywheel

INSPECTION AND ADJUSTMENT





- Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height.

Uneven limit:
0.7 mm (0.028 in)

- If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.





- Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.

- Check flywheel runout.

Maximum allowable runout (total Indicator Reading):
Flywheel (M/T) Less than 0.15 mm (0.0059 in)
Drive plate (A/T) Less than 0.20 mm (0.0079 in)

CAUTION: Do not allow any magnetic materials to conatact the ring gear teeth.

INSTALLATION





- Insert Tool into clutch disc hub when installing clutch cover and disc.

- Be careful not to allow grease to contaminate clutch facing.

- Tighten bolts in numerical order, in two steps.

First step:
10 - 20 Nm (1.0 - 2.0 kg-m, 7.2 - 14 ft-lb)
Final step:
22 - 29 Nm (2.2 - 3.0 kg-m, 16 - 22 ft-lb)