Clutch: Service and Repair
Clutch Cover, Clutch Disc and FlywheelRemoval
1. Dismount transaxle.
2. Hold flywheel stationary with special tool and remove clutch cover bolts (2), clutch cover (1) and clutch disc.
Special tool
(A): 09924-17811
3. When pulling out input shaft bearing (1) from flywheel (2), use the following special tool.
Special tool
(A): 09921-20210
(B): 09930-30104
Installation
NOTE: Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.
1. Install flywheel (2) to crankshaft and tighten bolts (1) to specification.
Special tool
(A): 09924-17811
Tightening torque
Flywheel bolts (a): 70 Nm (7.0 kgf-m, 51.0 ft. lbs.)
2. Using special tool, install input shaft bearing to flywheel.
Special tool
(A): 09913-76010
3. Aligning clutch disc with flywheel center by using special tool, install clutch cover (1) and bolts (2). Then tighten bolts (2) to specification.
NOTE:
^ While tightening clutch cover bolts, compress clutch disc with special tool (clutch center guide) by hand so that disc is centered.
^ Tighten cover bolts little by riffle evenly in diagonal order.
Special tool
(A): 09924-17811
(B): 09923-36320
Tightening torque
Clutch cover bolts (a): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
4. Slightly apply grease to input shaft (1), then join transaxle assembly with engine.
"A": Grease 99000-25210
NOTE: When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the spline mesh.
Clutch Cover, Clutch Disc and Flywheel Inspection
Input Shaft 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 rivet holes (2), replace clutch disc assembly (1).
Rivet head depth
Standard: 1.3 - 1.9 mm (0.051 - 0.074 inch)
Limit: 0.5 mm (0.02 inch)
Clutch Cover
1. Check diaphragm spring for abnormal wear or damage.
2. Inspect pressure plate for wear or heat spots.
3. 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.
Clutch Release System Removal and Installation
Removal
1. Remove release arm by loosening its nut and bolt.
2. Take out release bearing by turning release shaft.
3. Drive out No. 2 bush by using special tool and hammer. Release shaft oil seal will also be pushed out.
Special tool
(A): 09922-46010
4. Remove release shaft (1).
5. Pull No. 1 bush out by using special tools.
Special tool
(A): 09925-46010
(B): 09930-30104
Installation
1. Drive in a new No. 1 bush (1) by using special tools and hammer and then apply grease to bush inside.
Special tool
(A): 09943-88211
(B): 09923-46020
"A": Grease 99000-25010
2. Install release shaft with return spring.
3. Apply grease to No. 2 bush (1) inside and press-fit it by using the same special tool as in removal.
"A": Grease 99000-25010
Special tool
(A): 09922-46010
4. Coat grease to release shaft (3) oil seal (2) and then install it till it is flush with case surface. Use special tool for this installation and face seal lip downward (inside).
"A": Grease 99000-25010
Special tool
(B): 09925-98221
5. Caulk seal at A by using caulking (4) tool and hammer.
6. Hook return spring
7. Apply grease to release bearing inside diameter and release shaft arm (2), then set release bearing (1).
"A": Grease 99000-25010
8. Apply small amount of grease to input shaft (3) spline and front end as well.
"B": Grease 99000-25210
9. Set release arm to release shaft aligning their punch marks (1), then tighten nut (2) and bolt.
Tightening torque
Release arm nut (a): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
Clutch Release System Inspection
1. Check clutch release bearing for smooth rotation.
2. Inspect smoothness of release bearing retaining portion of transaxle case and correct or replace right case as necessary.
CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage.