Clutch: Service and Repair

SPECIAL TOOLS REQUIRED
^ 17 mm Hex Bit Cover Plug Remover/Installer
^ J-36668, Input Shaft Retaining Screw Remover/Installer
^ J-36644, Input Shaft Remover/Installer
^ J-6125-B, Slide Hammer
^ J-36554, Pressure Plate Spring Clamps
^ J-36536, Release Lever Shaft Bushing Remover/Installer
^ J-36190, Driver Handle
^ J-36546, Input Shaft Seal Installer

REMOVE OR DISCONNECT
1. Negative battery cable.




2. Measure threaded end of the clutch cable at the release lever. Record measurement so that the new cable can be preadjusted.
3. Clutch cable at release lever by removing the clip(2) and nut(4).
4. Raise vehicle and suitably support.
5. Left front wheel and tire assembly.
6. Plug, using a 17 mm Hex Bit at transaxle cover.




7. Internal snap ring (102) at end of input shaft and mark position of the input shaft in relation to the cluster gear.
8. Screw (103), using J-36668 at end of input shaft.




9. Install J-36644 with J-6125-B into end of input shaft. Disengage input shaft from cluster gear.
10. Clutch cover and bolts.




11. Push back clutch release lever and install one of the three J-36554 pressure spring clamps on pressure plate.
- Rotate flywheel 120° and install second clamp.
- Rotate flywheel 120° and install third clamp.

NOTE: Pressure plate and clutch disc cannot be removed without the three spring clamps installed.

12. Pressure plate washers and bolts. Support pressure plate when removing last bolt.
13. Clutch disc and pressure plate.




14. Release fork bolt (24) and washer.
15. Pull clutch release lever shaft upward out of the transaxle.




16. Fork and release bearing from bearing guide sleeve (19).
17. Bearing guide sleeve bolts (29) and bearing guide sleeve.
- Input shaft seal (17) from bearing guide sleeve (19).
- O-ring (18) from groove in transaxle case.




18. Release lever shaft bushings. Use J-36536 with J-36190 to drive out bushings.

INSTALL OR CONNECT




1. Release lever shaft bushings (22). Use J-36536 with J-36190 to drive in bushings, then coat bushing bores with grease No. 1052349, or equivalent.
2. Input shaft seal in bearing guide sleeve. Use J-36546 with a hammer.
3. Release bearing guide sleeve with 0-ring and bearing guide sleeve bolts. Tighten bolts to 5 Nm (45 in lb). Lightly coat sleeve surface and release bearing bore with grease No. 1052349, or equivalent.




4. Release bearing with clutch fork on bearing guide sleeve.
5. Release lever shaft from top of transaxle. Guide shaft through clutch fork.
6. Align shaft to fork and install washer and bolt. Tighten bolt to 35 Nm (26 ft lb).




7. Position the new pressure plate in a press. Apply enough pressure on fingers to install the three J-36554 pressure spring clamps at equal points around the pressure plate.
8. Position pressure plate and clutch disc to the flywheel with the long part of the clutch disc hub facing the transaxle. Lightly coat spline on clutch disc with grease specification No. 1052349, or equivalent.




9. Align marks on pressure plate with flywheel. Install two pressure plate washers and bolts to support and tighten bolts to 15 Nm (11 ft lb).




10. Align clutch disc splines with input shaft splines while aligning marks on input shaft with cluster gear. Install remaining pressure plate washers and bolts and tighten bolts to 15 Nm (11 ft lb).




11. Seat input shaft in cluster gear using J-36644 with J-6125-B.
12. Screw (103) at end of input shaft using J-36668 and tighten to 15 Nm (11 ft lb).
13. Snap ring (102) at end of input shaft with the sharp edge of snap ring facing cover.
14. Plug in transaxle cover using 17 mm hex bit. Apply pipe thread sealer with teflon to plug threads and tighten plug to 50 Nm (36 ft lb).
15. Three J-36554 Spring Clamps.
16. Clutch cover (15) with bolts and tighten bolts to 7 Nm (62 in lb).
17. Left front wheel and tire assembly.
18. Lower vehicle.
19. Clutch cable (3) to release lever.
20. Nut (4) on cable, to the measurement taken during removal.
21. Adjust clutch cable and install clip (2).
22. Negative battery cable.