Flywheel: Service and Repair

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL


Removal and Installation


COMPONENTS











CAUTION:
- Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage a seal of CSC and may cause clutch fluid leakage. Removal and Installation.
- Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
- When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
- Never clean clutch disc using solvent.

REMOVAL
1. Remove transaxle assembly from the vehicle. Removal And Installation (RS5F91R models), Transmission Assembly (RS6F94R models).
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.

INSPECTION AND ADJUSTMENT AFTER REMOVAL

Clutch Disc





- Measure clutch disc runout and spline backlash. If either measurement exceeds the specification, replace clutch disc.






- Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.





- Determine the wear limit of clutch facing (depth to the rivet head).
If measurement exceeds specifications, replace clutch disc.






Clutch Cover





- With the check clutch cover installed on vehicle Check the diaphragm spring toe height. If unevenness exceeds specifications, adjust the height using Tool (A).






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

NOTE:
- Worn thrust ring will generate a beating noise when tapped at the rivet using suitable tool.
- 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 clutch cover pressure plate to clutch disc contact surface, repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.

Flywheel Runout





- Check contact surface of flywheel for slight burns or discoloration.
Repair flywheel with emery paper.
- Check the flywheel runout. (HR16DE models), Inspection After Disassembly (MR18DE models).

CAUTION:
Measure flywheel outer face (not on knock pin and clutch cover mounting hole).

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 suitable clutch aligner (A).
- B: HR16DE
- C: MR18DE
4. Install clutch cover. Pre-tighten clutch cover bolts.
5. Tighten clutch cover bolts evenly in two steps in the order shown.
6. Install transaxle assembly. Removal And Installation (RS5F91R) or Transmission Assembly(RS6F94R).