Clutch: Service and Repair

REMOVAL
Prior to any operation that requires removal of the actuator, the master cylinder pushrod must be disconnected from the clutch pedal. Failure to disconnect pushrod will result in permanent damage to the actuator if the clutch pedal is depressed without resistance from clutch loads. Master cylinder pushrod bushing must also be replaced whenever it has been removed from the clutch pedal.
1. Disconnect battery ground cable.
2. Remove sound insulator from inside vehicle, then disconnect clutch master cylinder pushrod from clutch pedal.
3. On except 1989-90 models, disconnect quick connect fittings in clutch hydraulic line. Insert tool No. J-36221 or equivalent and depress white plastic sleeve to separate connection.
4. On all models, remove actuator to transaxle attaching nuts, then the actuator.
5. Remove transaxle assembly. Refer to procedure outlined under TRANSAXLE.
6. Place alignment marks on clutch cover assembly and flywheel to ensure reassembly in same position.
7. Loosen attaching bolts one turn at a time, until spring pressure is relieved.
8. Support clutch cover, then remove bolts.
9. Remove clutch cover and driven disc.

INSTALLATION
1. Position clutch disc and clutch cover, matching light side of clutch cover (marked with paint) with heavy side of flywheel (stamped with an X). Stamped letters on clutch disc identify ``flywheel side.'' Support clutch disc and clutch cover with clutch alignment arbor tool No. J-35822 or equivalent.
2. Install clutch cover to flywheel bolts in three holes marked ``L,'' then install remaining clutch cover to flywheel bolts, remove tool and Torque bolts to 15 ft. lbs. on 1989-90 models, 21 ft. lbs. in two steps on 1991 models and 15 ft. lbs. plus a 30° turn on 1992 models.
3. Lightly lubricate clutch fork ends which contact bearing and completely pack I.D. recess of release bearing with suitable grease. Levers on clutch fork shaft must bear on large ears of release bearing. Levers fit between large ears and small tangs on bearing. Fork shaft must move freely with bearing in place.
4. Tie actuator lever through actuator hole to studs, holding release bearing in position.
5. Install transaxle assembly. Clutch lever must not be moved toward flywheel until transaxle is bolted to engine.
6. On except 1989-90 models, align actuator and master cylinder quick connect fittings in hydraulic line and insert master cylinder fitting into actuator fitting until it locks in place.
7. On all models, remove tie from actuator lever.
8. Inspect actuator rod for lever bushing and replace if missing.
9. Install actuator on housing studs with pushrod bushing centered in pocket of internal lever in housing. It may require an axial load on the pushrod to compress the actuator piston spring.
10. Install actuator retaining nuts, Torquing evenly to 18 ft. lbs.
11. Install new bushing in master cylinder pushrod, lubricating before installation.
12. Connect master cylinder pushrod to clutch pedal, with bushing tangs snapped into pedal pin groove.
13. Depress clutch pedal several times, ensuring effort is normal and firm.
14. Readjust cruise control, if necessary, by pulling upward on clutch pedal with a force of not more than 20 lbs.
15. Install sound insulator and connect battery ground cable.