Unit Repair

CLUTCH DISC AND RELATED COMPONENTS
Removal Procedure





1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the left front wheel.
4. Remove the engine under covers.
5. Remove the transaxle from the vehicle.
6. Remove the pressure plate bolts and the pressure plate. Support the pressure plate when you remove the last bolt.





7. Remove the clutch disc.





8. Remove the release fork bolt.





9. Pull the clutch release shaft upward, out of the transaxle.





10. Remove the fork and the release bearing from the release bearing guide sleeve.





11. Remove the release lever shaft bushings.





12. Remove the bolts and the release bearing guide sleeve.





13. Remove the input shaft seal from the release bearing guide sleeve.





14. Remove the O-ring from the groove in the transaxle case.


Installation Procedure

- Tools Required
- J-36547 Input Shaft Seal Installer
- J-42474 Clutch Arbor





1. Install the O-ring into the groove in the case.





2. Install the input shaft seal into the release bearing guide sleeve. Use input shaft seal installer J-36547 with a hammer.





3. Install the release bearing guide sleeve and the bolts.
- Tighten the release bearing guide sleeve bolts to 5 Nm (45 inch lbs.).
4. Coat the sleeve surface with multipurpose grease.





5. Install the release lever shaft bushings. Coat the bushing bores with multipurpose grease.





6. Coat the release bearing bore with multipurpose grease.
7. Install the release bearing, with the clutch fork, onto the release bearing guide sleeve.





8. Install the release lever shaft from the top of the transaxle. Guide the shaft through the clutch fork.





9. Align the shaft to the fork and install the bolt.
- Tighten the clutch fork-to-release lever shaft bolt to 35 Nm (26 ft. lbs.).





10. Coat the spline on the clutch disc with multipurpose grease.
11. Align the pressure plate and the clutch disc onto the flywheel using the clutch arbor J-42474.
12. Install the pressure plate bolts.
- Tighten the pressure plate-to-flywheel bolts to 15 Nm (11 ft. lbs.).
13. Remove the clutch arbor J-42474.
14. Install the transaxle into the vehicle.
15. Install the engine under covers.
16. Install the left front wheel.
17. Lower the vehicle.
18. Connect the negative battery cable.