Clutch Removal and Inspection

CLUTCH REMOVAL AND INSPECTION

NOTICE: On vehicles equipped with an SIR system, disable the SIR system. (Refer to "Disabling the SIR System".)






1. Remove transaxle from vehicle. (Refer to "Manual Transaxle Removal".)
2. Remove release fork and bearing from transaxle by unsnapping fork from ball stud.






3. Separate release bearing from release fork by sliding the bearing from the fork.

NOTICE: The release bearing is packed with grease and must not be washed in solvent.

4. Check the release bearing for excessive play and for minimal bearing drag. Replace bearing if excessive play or no/little drag is found.






5. Use a feeler gauge to measure the distance between pressure plate and flywheel surfaces to determine clutch disc facing thickness. Replace disc if not within specification.

Thickness Range: 5.2 mm - 7.3 mm (0.205 - 0.287 in.)






6. Remove pressure plate to flywheel bolts.

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

7. Remove pressure plate and clutch disc.






8. Inspect pressure plate surface for excessive wear, chatter marks, cracks or overheating (indicated by blue discoloration). Replace pressure plate if damaged.

IMPORTANT: Black random spotting on friction surface of pressure plate is normal.

9. Check for pressure plate warpage using a straight edge and feeler gauge.

Maximum Warpage: 0.15 mm (0.006 in.)






10. Check clutch disc facings for oil or burnt spots. Replace clutch disk if necessary.
11. Check disc for loose damper springs, hub, or rivets. Replace disc if any are broken or excessively loose.






12. Inspect the flywheel ring gear for wear or damage. Replace flywheel if damaged.
13. Check flywheel to clutch disc contact surface for wear, cracks, chatter marks, or overheating (indicated by blue discoloration). Repair or replace flywheel if necessary.

IMPORTANT: Black random spotting on friction surface of flywheel is normal.

Minimum Flywheel Thickness: 28 mm (1.102 in.)






14. Measure flywheel runout using a dial indicator for at least two revolutions. Measure the runout at a diameter just inside the pressure plate bolt holes. Push the crankshaft forward to take up thrust bearing clearance. Repair or replace flywheel if not within specification.

Maximum Runout: 0.15 mm (0.006 in.)






15. Check the flywheel for warpage using a straight edge and feeler gauge.

Maximum Warpage: 0.15 mm (0.006 in.)






16. Remove flywheel-to-crankshaft bolts and remove flywheel.