Clutch: Service and Repair

Clutch, Pressure Plate, and Pilot Bearing Replacement

Special Tools

DT 46551 (DW210-010) Clutch Center Guide

Removal Procedure

Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).





1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer Transmission Replacement (D16 - Manual Transmission) for the D16 transaxle, or Transmission Replacement (Transmission Replacement) for the Y4M transaxle.
3. Remove the pressure plate bolts and the pressure plate.





Note: Support the pressure plate when you remove the last bolt.

4. Remove the clutch disc from the flywheel

Inspection Procedure




Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).


Visual Inspection of Clutch Disc
1. Inspect the worn or oily contamination on the clutch surface.
2. Inspect the damaged or weakened torsion spring.
3. Inspect for a warped or bent clutch disc. After inspection, replace the clutch disc, if necessary.

Clutch Disc Inspection
1. Measure the rivet head depth from the clutch disc surface.
2. Replace the clutch disc if the measured value is below the limit.

The rivet head depth standard is 1.2 mm (0.047 in), limit is 0.5 mm (0.020 in).





Clutch Disc Runout in Rotational Direction Inspection
1. Measure runout using the dial gauge.
2. If runout exceeds the limit, replace the clutch disc.

The disc runout limit in rotational direction - periphery - is 0.7 mm (0.028 in).





Visual Inspection of the Pressure Plate
1. Inspect for a worn diaphragm spring finger.
2. Inspect for a worn or cracked pressure plate surface.
3. Inspect for the polluted face by the oil. After inspection, replace the pressure plate if necessary.

Installation Procedure




1. Coat the spline on the clutch disc with multi-purpose grease.
2. Align the pressure plate and the clutch disc onto the flywheel using DT 46551.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the pressure plate bolts.

* For the hydraulic clutch type, tighten the bolts to 15 Nm (11 lb ft).
* For the cable clutch type, tighten the bolts to 18 Nm (13 lb ft).

4. Remove DT 46551 from the clutch assembly.
5. Install the transaxle into the vehicle. Refer to Transmission Replacement (D16 - Manual Transmission) for the D16 transaxle or Transmission Replacement (Transmission Replacement) for the Y4M transaxle.
6. Connect the negative battery cable.