Clutch: Service and Repair
Clutch Disc and CoverREMOVAL
1) Remove the transmission assembly from vehicle body.
5MT: Manual Transmission
6MT: Manual Transmission
2) Install the ST on flywheel.
ST 499747100 CLUTCH DISC GUIDE
3) Remove the clutch cover and clutch disc.
NOTE:
^ Take care not to allow oil on the clutch disc facing.
^ Do not disassemble the clutch cover and clutch disc.
^ Be sure to put alignment marks on the flywheel and clutch cover before removing clutch cover.
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) Install the clutch cover on flywheel and tighten the bolts to specified torque.
NOTE:
^ When reinstalling, align the alignment marks.
^ When installing a new clutch cover, 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.)
^ Note the front and rear of the clutch disc when installing.
^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order.
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly.
5MT: Manual Transmission Assembly
6MT: Manual 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.
NOTE:
Do not wash the clutch disc with any cleaning fluid.
2) Hardened facing
Correct by using emery paper or replace.
3) Oil leakage on facing
Replace the clutch disc 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, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
5) If worn spline, loose rivets or damper spring failure is found, replace the clutch disc.
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 center of diaphragm spring
