Clutch Disc: Service and Repair

Clutch Disc and Cover

REMOVAL

1. Install crankshaft stopper on flywheel using special tool: (498497100).
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.

INSPECTION

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.

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.

FLYWHEEL

Since this bearing is grease sealed 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

Rotate 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)


INSTALLATION

1. Install flywheel.
2. Install crankshaft stopper, and tighten the flywheel attaching bolts to the specified torque.

Tightening torque: 69 - 75 Nm (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, using special tool: 499747100.
4. Install clutch cover CP on flywheel and tighten bolts to the specified torque.

Tightening torque: 14.2 - 17.2 Nm (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.