Clutch: Service and Repair

Clutch Assembly Replacement

^ Tools Required
- J 43482 Clutch Alignment Arbor

Removal Procedure





1. Remove the transaxle.
2. Inspect the actuator release bearing minimal bearing drag.
3. Replace the actuator assembly if no or little drag is found.

4. Important: Remove the bolts in a progressive crisscross pattern to prevent warping of the cover stamping.

Remove the pressure plate assembly to flywheel bolts.
5. Remove the pressure plate assembly and clutch disc.





6. Important: Random black spotting on the friction surface of the clutch pressure plate assembly is normal.

Inspect the clutch pressure plate assembly surface for the following conditions:
^ Excessive wear
^ Chatter marks
^ Cracks
^ Overheating - indicated by blue discoloration
7. Replace the clutch pressure plate assembly if damaged.
8. Using a straight edge and a feeler gage, inspect the clutch pressure plate assembly for warpage.
Maximum warpage: 0.15 mm (0.006 inch)





9. Inspect the clutch disc facings for oil or burnt spots.
10. Replace the clutch disc if necessary.
11. Inspect the clutch disc for the following conditions:
^ Loose damper springs
^ Hub
^ Rivets
12. Replace the clutch disc if any components are broken or excessively loose.





13. Inspect the flywheel ring gear for wear or damage.
14. Replace the flywheel if damaged.

15. Important: Random black spotting on the friction surface of the flywheel is normal.

Inspect the flywheel to clutch disc contact surface for the following conditions:
^ Wear
^ Cracks
^ Chatter marks
^ Overheating - indicated by blue discoloration
16. Repair or replace the flywheel if necessary.





17. Using a dial indicator, for at least two revolutions, measure flywheel runout.
Maximum runout: 0.15 mm (0.006 inch)
18. Repair or replace the flywheel if not within specification.





19. Using a straight edge and a feeler gage, inspect the flywheel for warpage.
Maximum warpage: 0.15 mm (0.006 inch)





20. If the flywheel is being replaced, remove and discard the flywheel-to-crankshaft bolts and remove the flywheel.

Installation Procedure





1. Notice: Refer to Fastener Notice in Service Precautions.

Install the flywheel and the new flywheel-to-crankshaft bolts. Hand start the bolts.
2. Tighten the flywheel-to-crankshaft bolts in a crisscross pattern.
^ Tighten the bolts to 53 Nm plus 25 degrees (39 ft. lbs.) plus 25 degrees.





3. Important: Ensure that the straps on the clutch pressure plate fit into the slots on the flywheel, flexplate.

Install the clutch disc and the clutch pressure plate assembly to the flywheel.
4. Loosely install the clutch pressure plate bolts.





5. Install the J 43482 in the clutch disc and push in until it bottoms out in the crankshaft.





6. Important: Do not tighten the pressure plate assembly bolts more than half a turn at a time or the pressure plate assembly may warp.

Tighten the pressure plate assembly bolts using a progressive crisscross pattern to prevent warping of the pressure plate assembly.
^ Tighten the bolts to 24 Nm (17 ft. lbs.).

7. Important: Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

Lightly lubricate the input shaft splines with clutch spline lubricant P/N 21005995 or equivalent.
8. Install the transaxle.
9. Bleed the clutch hydraulic system.