Clutch: Service and Repair

Removal





1) Hold flywheel stationary with special tool (A) and remove clutch cover bolts (1), clutch cover (2) and clutch disc.





2) Pull out input shaft bearing (1) by using special tool (13) and wrench.
3) Remove release bearing and release fork.

Installation

NOTE: Before installation, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly and inspect the parts.





1) Install flywheel (1) to crankshaft and tighten bolts (2) to specification.
Special tool (A): 09924-17810
"A": Grease 99000-31110
Tightening torque
Flywheel bolt (for G16 engine model) (a): 78 Nm (7.8 kgf-m, 56.5 ft. lbs.)
Flywheel bolt (for J20 and H25 engine models) (a): 70 Nm (7.0 kgf-m, 50.5 ft. lbs.)





2) Using special tool (B), install input shaft bearing to flywheel.





3) Aligning clutch disc to flywheel center by using special tool (C), install clutch cover (1) and bolts. Then tighten bolts to specification.

NOTE:
^ While tightening clutch cover bolts, compress clutch disc with special tool (C) by hand so that disc centered.
^ Tighten cover bolts little by little evenly in diagonal order.

4) Install clip (2) to release fork (1) and apply grease.
"A": Grease 99000-25010
5) Install release fork (1) and release bearing as shown in figure.
6) Slightly apply grease to input shaft (3) and install clutch disc.
"B": Grease 99000-25210





7) Join transmission transfer assembly with engine.

NOTE: Turn crankshaft with wrench from front while inserting transmission input shaft (3) to clutch disc until splines mesh.

Inspection
Input Shaft Bearing and Release Bearing Check bearing for smooth rotation and replace it if abnormality is found.

Clutch Disc





^ Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.

Clutch Cover
^ Check diaphragm spring for abnormal wear or damage.
^ Inspect pressure plate for wear or heat spots. If abnormality is found, replace it as assembly. Do not disassemble it into diaphragm and pressure plate.

Flywheel
^ Check surface contacting clutch disc for abnormal wear or heat spots. Replace or repair as required.