CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R, C66MX-R]

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Special Service Tool (SST)

49 E011 1A0
 
Ring gear brake set
49 SE01 310A
 
Clutch disc center tool
49 1285 071
 
Bearing puller

Replacement Part

Lock bolt
 
Quantity: 6
 
Location of use: Flywheel (Without cylinder deactivation)
Pilot bearing
 
Quantity: 1
 
Location of use: Flywheel (Without cylinder deactivation)
Lock bolt
 
Quantity: 6
 
Location of use: Dual-mass flywheel (With cylinder deactivation)
Pilot bearing
 
Quantity: 1
 
Location of use: Dual-mass flywheel (With cylinder deactivation)
Clutch cover
 
Quantity: 1
 
Location of use: Dual-mass flywheel (With cylinder deactivation)
Clutch disc
 
Quantity: 1
 
Location of use: Dual-mass flywheel (With cylinder deactivation)

Oil and Chemical Type

Grease
 
Type: Molybdenum grease


Without Cylinder Deactivation

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66MX-R].)

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].)

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1
Boot
2
Clutch release fork
3
Clutch release collar
4
Pivot pin
5
Clutch cover
(See Clutch cover and clutch disc removal note.)
(See Clutch disc and clutch cover installation note.)
6
Clutch disc
(See Clutch cover and clutch disc removal note.)
(See Clutch disc and clutch cover installation note.)
7
Pilot bearing
(See Pilot bearing removal note.)
(See Pilot bearing installation note.)
8
Plate
9
Flywheel
(See Flywheel removal note.)
(See Flywheel Installation Note.)


Clutch cover and clutch disc removal note

1.  Hold the clutch unit using the SSTs (49 SE01 310A, 49 E011 1A0).

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2.  Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

3.  Remove the clutch cover and clutch disc.


Pilot bearing removal note

Note
•  The pilot bearing does not need to be removed unless you are replacing it.

1.  Use the SST (49 1285 071) to remove the pilot bearing.

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Flywheel removal note

1.  Hold the flywheel using the SST (49 E011 1A0).

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2.  Remove the lock bolts, and remove the plate and the flywheel.

3.  Inspect for oil leakage from the crankshaft rear oil seal.

•  If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL REPLACEMENT [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)


Flywheel Installation Note

1.  Degrease and clean the flywheel.

2.  Clean the crankshaft thread holes.

3.  Install the flywheel and the plate to the crankshaft, and temporarily tighten a new lock bolts.

4.  Hold the flywheel using the SST (49 E011 1A0).

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5.  Tighten the lock bolts completely in the order shown in the figure in the following 3 steps.

Tightening torque
Step 1: 46—54 N·m {4.7—5.5 kgf·m, 34—39 ft·lbf}
Step 2: 76—84 N·m {7.8—8.5 kgf·m, 57—61 ft·lbf}
Step 3: 108—116 N·m {11.1—11.8 kgf·m, 80—85 ft·lbf}


Pilot bearing installation note

1.  Install new pilot bearing to the specified position using the following tools.

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Tool
Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm {0.79—0.86 in})
•  Use the adapter with the 20 mm {0.79 in} side of the A160M7 (20—22 mm {0.79—0.86 in}) facing the pilot bearing side.
Substitution tool
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Standard position
Distance A of pilot bearing from crankshaft end: 1.5—2.5 mm {0.060—0.098 in}
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Clutch disc and clutch cover installation note

Caution
•  Do not apply grease to the spline end (transaxle side). If excessive grease is applied, clutch-slip may occur.

1.  Apply grease to the spline (engine side) of the clutch disc.

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2.  Insert the clutch disc into the primary shaft and wipe off the excess grease protruding from the spline.

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3.  Slide the clutch disc three times in the directions of the arrows shown in the figure to engage to grease.

4.  Remove the clutch disc from the primary shaft and wipe off the excess grease protruding from the spline.

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5.  Verify that grease has been lightly applied to the clutch disc and the spline of the primary shaft.

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6.  Hold the clutch disc position using the SST (49 SE01 310A).

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7.  Hold the clutch unit using the SST (49 E011 1A0).

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8.  Using the following procedure, install the clutch disc and clutch cover.

(1)  Temporarily tighten the bolts in the order shown in the figure.
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(2)  Tighten the bolts completely in two or three steps in the order shown in the figure and install the clutch disc and cover.
Tightening torque
25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}

9.  Remove the SSTs (49 SE01 310A, 49 E011 1A0).


With Cylinder Deactivation

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66MX-R].)

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Add the specified amount of manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].)

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1
Boot
2
Clutch release fork
3
Clutch release collar
4
Pivot pin
5
Clutch cover
(See Clutch cover and clutch disc removal note.)
(See Clutch disc and clutch cover installation note.)
6
Clutch disc
(See Clutch cover and clutch disc removal note.)
(See Clutch disc and clutch cover installation note.)
7
Pilot bearing
(See Pilot bearing removal note.)
(See Pilot bearing installation note.)
8
Dual-mass flywheel
(See Flywheel removal note.)
(See Flywheel Installation Note.)


Clutch cover and clutch disc removal note

Caution
•  The removed clutch cover and clutch disc for the C66M(X)-R cannot be reused. If the clutch cover and clutch disc are removed, replace the clutch cover and clutch disc as a single unit with a new part.

1.  Hold the clutch unit using the SSTs (49 SE01 310A, 49 E011 1A0).

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2.  Loosen each bolt in small steps and diagonally.

3.  Remove the clutch cover and clutch disc.


Pilot bearing removal note

Note
•  The pilot bearing does not need to be removed unless you are replacing it.

1.  Use the SST (49 1285 071) to remove the pilot bearing.

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Dual-mass flywheel removal note

1.  Hold the dual-mass flywheel using the SST (49 E011 1A0).

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2.  Remove the lock bolts, and remove the plate and the dual-mass flywheel.

3.  Inspect for oil leakage from the crankshaft rear oil seal.

•  If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL REPLACEMENT [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)


Dual-mass flywheel installation note

1.  Clean the dual-mass flywheel.

Caution
•  When cleaning the dual-mass flywheel, use a dry cloth with no fluid.
•  Do not clean between the primary flywheel and secondary flywheel. Clean only the bolt connecting areas and the contact surface of the clutch.

2.  Clean the crankshaft thread holes.

3.  Install the dual-mass flywheel to the crankshaft, and temporarily tighten a new lock bolts.

4.  Hold the dual-mass flywheel using the SST (49 E011 1A0).

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5.  Tighten the lock bolts completely in the order shown in the figure in the 3 steps.


Pilot bearing installation note

1.  Install new pilot bearing to the specified position using the following tools.

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Tool
Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm {0.79—0.86 in})
•  Use the adapter with the 20 mm side of the A160M7 (20—22 mm {0.79—0.86 in}) facing the pilot bearing side.
Substitution tool
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Specified position
Distance A of pilot bearing from crankshaft end: 1.5—2.5 mm {0.060—0.098 in}
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Clutch disc and clutch cover installation note

Caution
•  Do not apply grease to the spline end (transaxle side). If excessive grease is applied, clutch-slip may occur.

1.  Apply grease to the spline (engine side) of the clutch disc.

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2.  Insert the clutch disc into the primary shaft and wipe off the excess grease protruding from the spline.

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3.  Slide the clutch disc three times in the directions of the arrows shown in the figure to engage to grease.

4.  Remove the clutch disc from the primary shaft and wipe off the excess grease protruding from the spline.

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5.  Verify that grease has been lightly applied to the clutch disc and the spline of the primary shaft.

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6.  Hold the clutch disc position using the SST (49 SE01 310A).

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7.  Hold the clutch unit using the SST (49 E011 1A0).

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8.  Using the following procedure, install the clutch disc and clutch cover.

(1)  Temporarily tighten the bolts in the order shown in the figure.
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(2)  Tighten the bolts completely in four or five steps in the order shown in the figure and install the clutch disc and cover.

9.  Remove the SSTs (49 SE01 310A, 49 E011 1A0).