Clutch Disc: Service and Repair
Modular Clutch AssemblyREMOVAL
1. Remove transaxle from vehicle.
Modular Clutch Assembly:
2. Remove modular clutch assembly (Fig. 58) from transaxle input shaft.
3. 2.4L Turbo models: Disassemble modular clutch assembly. Remove six (6) pressure plate-to-flywheel bolts (Fig. 59). Remove pressure plate and disc from flywheel.
INSPECTION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/ road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black.
GREASE CONTAMINATION
Grease contamination is usually a product of overlubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel.
INSTALLATION
1. 2.4L Turbo models: Install clutch disc to flywheel with "Flywheel Side" oriented towards flywheel. Align clutch disc to flywheel by ensuring equal distance between disc and flywheel lip exists in three places as shown in (Fig. 60). Install pressure plate to flywheel, locating on dowels (Fig. 59) and making sure not to disturb clutch disc. Install and torque six (6) pressure plate-to-flywheel bolts to 28 Nm (250 inch lbs.). Visually verify clutch disc alignment.
Modular Clutch Assembly:
2. All models: Install clutch module (Fig. 58) onto input shaft.
3. Install transaxle into vehicle.