Clutch Disc: Service and Repair

Clutch Disc and Cover

REMOVAL
1) Remove the transmission assembly from vehicle body.





2) Install the ST on flywheel.
ST 499747100 CLUTCH DISC GUIDE
3) Remove the clutch cover and clutch disc.

CAUTION:
^ Take care not to allow oil on the clutch disc facing.
^ Do not disassemble either the clutch cover or clutch disc.

INSTALLATION





1) Insert the ST into the clutch disc and install them on the flywheel by inserting the ST end into the pilot bearing.
ST 499747100 CLUTCH DISC GUIDE





2) Install the clutch cover on flywheel and tighten bolts to the specified torque.

NOTE:
^ When installing the clutch cover on the flywheel, position the clutch cover so that there is a gap of 120° or more between white paint marks on the flywheel and clutch cover. (white paint marks indicate the directions of residual unbalance.)
^ Note the front and rear of the clutch disc when installing.
^ Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross method.

Tightening torque: 15.7 Nm (1.6 kgf-m, 11.6 ft. lbs.)
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly.

INSPECTION
CLUTCH DISC





1) Facing wear:
Measure the depth of rivet head from the surface of facing. Replace if the facings are worn locally or worn down to less than the specified value.
Depth of rivet head:
Limit of sinking 0.3 mm (0.012 inch)

CAUTION: Do not wash the clutch disc with any cleaning fluid.

2) Hardened facing: Correct by using emery paper or replace.





3) Oil soakage on facing: Replace the 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.
ST 499747100 CLUTCH DISC GUIDE
Limit for deflection:
Non-turbo model: 1.0 mm (0.039 inch) at R = 107 mm (4.21 inch)
Turbo model: 0.8 mm (0.031 inch) at R = 110 mm (4.33 inch)





5) Worn spline, loose rivets and torsion spring failure:
Replace defective parts.

CLUTCH COVER

NOTE: 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 the 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.