Clutch Replacment

Special Tools
- Flywheel Locking Tool No. 999 5112, or equivalent
- Clutch Centering Tool No. 999 5487, or equivalent

- Refer to special tool section for additional tool information.

Preparations
- Before replacing clutch disc and pressure plate, follow steps 1 through 26 of Transmission Removal. Service and Repair


Procedure





1. Removing clutch disc and pressure plate.
- Use Flywheel Locking Tool No. 999 5112, or equivalent, to lock flywheel.
- Remove the six bolts, slackening them in rotation.
- Remove pressure plate and disc.





2. Removing throwout (release) bearing
- Remove throwout (release) bearing from sleeve and fork.
Remove fork and dust cap.





3. Clean parts.
- Check:
Throwout bearing.
Rotate bearing under light pressure; bearing should rotate freely and silently.
Fork for signs of cracking or wear.
That the dust cap is intact.





4. Checking pressure plate and flywheel
- Check carefully for signs of overheating damage, cracks, scoring or other damage to the friction surface.
- Check that the diaphragm spring is not split or damaged.
Pressure plate cannot be dismantled: replace as complete unit.





5. Checking pressure plate for warpage.
- Pressure plate does not need replacing if warpage does not exceed 0.2 mm.

NOTE: Warpage is only allowed in one direction (see illustration).





6. Check that flywheel is free from cracks and heavy scoring.
- Replacing flywheel, refer to Engine.





7. Checking clutch disc.
- Disc must be completely free of oil and dirt.
- Damper springs in center of plate must be in good condition.
- Plate hub should be free to move slightly.
- Replace disc if necessary.





8. Installing throwout (release) bearing fork.
- Lubricate ball joint with paste, part No.1161246-2, or equivalent.
- Install:
Throwout (release) bearing fork and dust cap
Throwout (release) bearing.
Install throwout (release) bearing in fork and on sleeve.
Put a strap around the fork to hold the throwout (release) bearing in place during installation.

NOTE: Do not grease primary shaft or throwout (release) bearing sleeve.

Special Tools And Equipment For Clutch, Front Driveshaft And Transmission Service (Part 7 Of 20):

9. Installing disc and pressure plate on flywheel.
- Install disc assembly, flat side towards flywheel.
Use Clutch Centering Tool No. 999 5487, or equivalent.
- Install clutch bolts, tightening carefully in rotation so clutch moves forward into locating pin and rests evenly against flywheel.
Now tighten bolts in rotation to: 25 Nm.
- Remove centering tool and locking tool .
- Refer to steps 1 through 25 of Transmission, Installation. Service and Repair