Flywheel: Service and Repair

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL


Removal and Installation


CAUTION:
- If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage CSC seal and may cause clutch fluid leakage.
- Be careful not to apply any grease to the clutch disc facing, pressure plate surface and flywheel surface.

REMOVAL
1. Remove transaxle assembly from the vehicle. (RS6F94R) or Transmission Assembly (RS6F52A), Transmission Assembly (RS6F52H).
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.

INSPECTION AFTER REMOVAL

Clutch Disc





- Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to be measured : Refer to Clutch Disc.

- Measure backlash to clutch disc spline and main drive gear spline at the circumference of clutch disc. If it is outside the specification, replace clutch disc.

Maximum allowable spline backlash (at outer edge of disc) : Refer to Clutch Disc.






- Measure the depth "A" to clutch disc facing rivet heads, using a calipers. If it exceeds the allowable wear limit, replace clutch disc.

Facing wear limit (depth to the rivet head) A : Refer to Clutch Disc.


Clutch Cover
- Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.

NOTE:
- Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
- Broken thrust ring will make a clinking sound when cover is shaken up and down.
- If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and dust caused by abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.

CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage to the clutch may result. Excessive grease may cause slip or shudder. If it adheres to CSC seal, it will cause clutch fluid leakage. Wipe off excess grease.





3. Install clutch disc, using a clutch aligner (A) [Commercial service tool].
4. Install clutch cover and then temporarily tighten clutch cover mounting bolts.
5. Tighten clutch cover mounting bolts to the specified torque evenly in two steps in the numerical order as shown.
6. Install transaxle assembly. (RS6F94R), Transmission Assembly (RS6F52A) or Transmission Assembly (RS6F52H).

INSPECTION AFTER INSTALLATION

Clutch Cover





Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height, using the diaphragm adjusting wrench (A) [SST: ST20050240 ( - )].

Tolerance for diaphragm spring lever unevenness : Refer to Clutch Cover.