Clutch: Service and Repair
1. Remove transmission as described under TRANSMISSION.
1. General
A: PRECAUTION
When servicing clutch system, pay attention to the following items.
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toeboard hole and route it smoothly. Adjustment is done by moving the outer cable.
6) Make sure not to let the clutch chatter when starting forward or rearward. If clutch chattering occurs, readjust so that the bend of clutch outer cable becomes flatter.
B: ON-CAR SERVICE
1) Remove release lever return spring from lever.
2) Adjust spherical nut so that the play is within the specified value at the lever end (center of spherical nut). Take care not to twist the cable during adjustment
Play: 3-4mm (0.12-0.16 in)
Full stroke: 25.5-27 (1.004-1.063)
3) Upon completion of adjustment, securely lock spherical nut with lock nut.
4) Install return spring on lever. Hook the long hook side of the return spring with the lever.
5) Depress clutch pedal to assure there is no abnormality in the clutch system.
2. Release Bearing and Lever
A. REMOVAL
1) Remove the two clips from clutch release lever and remove release bearing. Be careful not to deform clips.
2) Remove release lever seal.
3) Remove release lever retainer spring from release lever pivot with a screwdriver by accessing it through clutch housing release lever hole. Then remove release lever.
B: INSPECTION
1. RELEASE BEARING
Since this bearing is greasesealed and is of a nonlubrication type, do not wash with gasoline or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by applying force in the radial direction.
2) Check the bearing for smooth rotation by applying pressure in the thrust direction.
3) Check wear and damage of holder surface contacting with lever.
2. RELEASE LEVER
Check lever pivot portion and the point of contact with holder for wear.
C: INSTALLATION
Before or during assembling, lubricate the following points with a light coat of grease.
a. Inner groove of release bearing.
b. Contact surface of lever and pivot.
c. Contact surface of lever and bearing.
d. Transmission main shaft spline. (Use grease containing molybdenum disulphide.)
1) Install retainer spring into lever.
2) While pushing lever to pivot and twisting it to both sides, fit retainer spring onto the constricted portion of pivot. Confirm that retainer spring is securely fitted by observing it through the main case hole.
3) Install release bearing and fasten it with two clips.
4) Install release lever sealing.
5) After remounting engine and transmission on body, make adjustment of the clutch release lever end play. Take care not to twist the cable during adjustment. 6) Install release lever return spring. Hook up the long hook side of the return spring with the lever.
3. Clutch Disc and Cover
A: REMOVAL
1) Install CRANKSHAFT STOPPER on flywheel.
Special tool: CRANKSHAFT STOPPER (4984971OO)
2) Remove clutch cover and clutch disc.
a. Take care not to allow oil on the clutch disc facing.
b.Do not disassemble either clutch cover CP or clutch disc CP.
3) Remove flywheel.
B: INSPECTION
1.CLUTCH DISC
1) Facing wear Measure the depth of rivet head from the surface of facing. Replace if facings are worn locally or worn down to less than the specified value. Depth of rivet head
Standard value 1.4 mm (0.055 in)
Limit of sinking 0.3 mm (0.012 in)
Do not wash clutch disc with any cleaning fluid.
2) Hardened facing Correct by using emery paper or replace.
3) Oil soakage on facing Replace clutch disc and inspect transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.
4) Deflection on facing If deflection exceeds the specified value at the outer circumference of facing, repair or replace.
Limit for deflection: 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
5) Worn spline, loose rivets and torsion spring failure Replace defective parts.
2. CLUTCH COVER
Visually check for the following items without disassembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center of diaphragm spring.
3) Damaged or worn disc contact surface of pressure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
3. FLYWHEEL
Since this bearing is greasesealed and is of a nonlubrication type, do not wash with gasoline or any solvent.
1) Damage of facing and ring gear If defective, replace flywheel.
2) Smoothness of rotation Potate ball bearing applying pressure in thrust direction. If noise or excessive play is noted, replace ball bearing as follows:
(1) Drive out ball bearing from flywheel.
(2) Press bearing into flywheel until bearing end surface is flush with clutch disc contact surface of flywheel. Do not press inner race.
Special tool: SNAP RING PRESS (899754112)
C: INSTALLATION
1) Install flywheel.
2) Install CRANKSHAFT STOPPER, and tighten the fly wheel attaching bolts to the specified torque.
Tightening torque:
69-75 N.m (7.0-7.6 kg-m, 51-56 ft-lb)
3) Insert CLUTCH DISC GUIDE into the clutch disc and install them on the flywheel by inserting the GUIDE end into the pilot bearing.
4) Install clutch cover CP on flywheel and tighten bolts to other specified torque.
Tightening torque: 14.2-17.2 N.m (1.45-1.75 kg-m, 10.5-12.7 ft-lb)
a. When installing the clutch cover on the flywheel, position the clutch cover so that there is a gap of 120° or more between "0" marks on the flywheel and clutch cover. ("0" marks indicate the directions of residual unbalance.)
b. Note the front and rear of the clutch disc when installing.
c. Tighten clutch cover installing bolts gradually. Each bolt should be tightened in a crisscross fashion to the specified torque.