CLUTCH UNIT REMOVAL/INSTALLATION [F35M-R]

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1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

2.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

3.  Remove the front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION).)

4.  Remove the fresh-air duct and air cleaner component as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZJ, ZY].)

5.  Remove the fitting bolts of the EGR pipe (intake manifold side) using the procedure indicated in the figure. (See EGR PIPE REMOVAL/INSTALLATION [ZJ, ZY].)

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6.  Suspend the EGR pipe (intake manifold side) with a cable in place out of the way.

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7.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [F35M-R].)

8.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].)

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [F35M-R].)

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [F35M-R].)

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1	Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].)
2	Clutch release collar
3	Boot
4	Clutch release fork
5	Clutch cover (See Clutch Cover and Disc Removal Note.) (See Clutch Cover Installation Note.)
6	Clutch disc (See Clutch Cover and Disc Removal Note.) (See Clutch Disc Installation Note.)
7	Pilot bearing (See Pilot Bearing Removal Note.) (See Pilot Bearing Installation Note.)
8	Flywheel (See Flywheel Removal Note.) (See Flywheel Installation Note.)

Clutch Cover and Disc Removal Note

1.  Install the SSTs.

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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 disc.

Pilot Bearing Removal Note

Note

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

1.  Use the SST to remove the pilot bearing.

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Flywheel Removal Note

1.  Hold the flywheel using the SST.

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2.  Loosen the lock bolts uniformly in the order of the numbers shown in the figure and remove 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 [ZJ, ZY].)

Flywheel Installation Note

Caution

•  Clean the crankshaft threads before tightening the bolts. The threads may be damaged if the bolts are tightened with any old sealant remaining.

1.  Clean the crankshaft thread holes before installing the new flywheel lock bolts.

2.  Install the flywheel to the crankshaft.

3.  Hand-tighten the flywheel lock bolts.

4.  Install the SST to the flywheel.

5.  Tighten the lock bolts uniformly in the order of the numbers shown in the figure and install the flywheel.

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Pilot Bearing Installation Note

1.  Use the SSTs to install the pilot bearing.

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Clutch Disc Installation Note

1.  Clean the splines of the clutch disc and primary shaft gear with a brush.

2.  Apply a small amount of molybdenum grease to the splines.

3.  Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.  Install the SST, tighten the bolts uniformly in the order of the numbers shown in the figure, and install the clutch cover.

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