Clutch: Service and Repair

Clutch Pressure and Driven Plate Replacement

Special Tools

Snap On(R) A145 Clutch Alignment Set or Equivalent

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement (With ZOK) (Aisin AR5 - Maunal Transmission)Transmission Replacement (Without ZOK) (Transmission Replacement (Without ZOK)).




2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved.




3. Remove the clutch cover and the clutch disc.

Installation Procedure

1. Adjust the clutch pressure plate, if necessary. Refer to Clutch Pressure Plate Adjustment (Adjustments).




2. Install the clutch disc and the clutch cover.
3. Hand start the clutch cover to flywheel bolts, leaving the clutch cover loose enough to reposition for alignment.




4. Install the correct alignment tool from the Snap On(R) A145, Clutch Alignment Set, or equivalent, in order to support the clutch cover to the flywheel assembly.





Caution: Refer to Fastener Caution (Fastener Caution).

5. Tighten the clutch cover to flywheel bolts in the sequence shown.

Tighten the bolts to 30 Nm (22 lb ft).

6. Recheck each bolt torque using the tightening sequence.
7. Remove the Snap On(R) A145 tool.

Note: Excessive amounts of lubricant on the input shaft splines may contaminate the clutch disc and cause clutch shudder.

8. Lubricate the inside diameter of the bearing.
9. Install the transmission. Refer to Transmission Replacement (With ZOK) (Aisin AR5 - Maunal Transmission)Transmission Replacement (Without ZOK) (Transmission Replacement (Without ZOK)).
10. Bleed the hydraulic system. Refer to Hydraulic Clutch System Bleeding (Service and Repair).
11. Connect the negative battery cable.