Clutch Disc: Service and Repair
Clutch Disc and CoverREMOVAL
1. Remove the transmission assembly from vehicle body.
2. Install the ST on flywheel.
ST 499747100 CRANKSHAFT STOPPER
3. Remove the clutch cover and clutch disc.
NOTE:
^ 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 clutch disc and install them on the flywheel by inserting the ST end into pilot bearing.
NOTE: When installing the clutch disc, be careful to its direction.
ST 499747100 CLUTCH DISC GUIDE
2. Position 0 marks on clutch cover and flywheel 120° apart, and then tighten the clutch cover installation bolts diagonally.
NOTE:
^ 0 marks indicate the directions of residual unbalance.
^ Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross fashion.
Tightening torque: 16 Nm (1.6 kgf-cm, 11.8 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 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)
NOTE: 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 (A) and inspect the 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, replace.
ST 499747100 CLUTCH DISC GUIDE
Limit for deflection:
Non-TURBO model, 0.8 mm (0.031 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.
If defective, replace clutch disc.
CLUTCH COVER
NOTE: Visually check for the following items without disassembling, and replace if defective.
1. Loose thrust rivet.
2. Damaged or worn bearing contact area at center of diaphragm spring.