Clutch: Service and Repair

Clutch assembly
Removal





Notice:
a) Remove clutch release cylinder with clutch line connected.
b) Do not remove pilot bearing unless necessary.

1. Remove transaxle assembly.





2. Install SST (OK130 430 010/ OK590 111 004).





3. Loosen each bolt one turn at a time, in a crisscross pattern, until spring tension is released. Proceed to remove clutch cover assembly and disc.
4. Remove pilot bearing with SST(OK401 111 012), if necessary.

Notice: After removing flywheel, inspect for oil leakage past crankshaft rear oil seal If necessary, replace oil seal.





5. Measure flywheel runout with a dial indicator. Replace flywheel if runout is excessive.
Runout: 0.008 inch (0.2 mm) maximum
6. Hold flywheel with SST(OK590 111 004).





7. Remove six bolts and then remove flywheel.

Inspection
Release bearing

Notice: The clutch release bearing is sealed, and should not be washed in solvent.





1. Turn bearing while applying force in axial direction. If bearing sticks or has excessive resistance, replace it.

Clutch cover
1. Inspect contact surface of pressure plate for scoring, cracks and burning. Resurface or replace as necessary.





2. Inspect release bearing contact surface (on the diaphragm spring fingers) for wear and cracks. If there is wear or cracks on diaphragm fingers, replace clutch cover assembly.

Clutch disc
1. Inspect lining surface for burning oil contamination or otherwise damage. Replace clutch disc if it is burned, oil soaked or other damaged.





2. Inspect for loose clutch facing rivets and damaged torsional dampers. Replace clutch disc if either is faulty.





3. Measure depth of lining from clutch face to head of a rivet with calipers. Replace clutch disc if thickness on either side is less than minimum.
Thickness: 0.012 inch (0.3 mm) minimum





4. Measure clutch disc runout with a dial indicator. Replace clutch disc if runout is excessive.
Runout: 0.027 inch (0.7 mm) maximum

Pilot bearing





1. Turn bearing while applying force in axial direction. If bearing sticks or has excessive resistance, replace it.

Flywheel

Notice: Minor scoring or burning should be removed with emery cloth.





1. Inspect contact surface of flywheel for scoring, cracks and burning; resurface or replace as necessary.
2. Inspect starter ring gear teeth for wear or damage. If necessary, replace ring gear.

Replacement

Notice: Install pilot bearing flush with flywheel.





1. Install new bearing with a suitable tool.
Bearing outer diameter: 1.378 inch (35 mm)
2. Wipe bolts clean and apply sealant to bolt threads.
3. Install flywheel and SST(OK590 111 004).





4. Tighten bolts in pattern shown below.
Tightening torque: 70.8 - 75.9 ft. lbs. (96.1 - 103.0 Nm, 9.8 - 10.5 kg.m)
4. Clean clutch disc internal splices; then apply a thin coat of molybdenum disulfide grease to the splines.





5. Hold clutch disc in position with SST(OK130 160 010).
6. Align dowel holes of clutch cover assembly with flywheel dowels.





7. Tighten bolts evenly and gradually in pattern shown below.
Tightening torque: 13.0 - 19.5 ft. lbs. (17.6 - 26.5 Nm, 1.8 - 2.7 kg.m)
8. Install transaxle assembly.