Clutch
- TOOLS REQUIRED- SA9145T M/T Clutch Aligner
REMOVAL AND INSPECTION
1. Remove transaxle from vehicle.
2. Remove release fork and bearing from transaxle by unsnapping fork from ball stud.
3. Separate release bearing from release fork by sliding the bearing from the fork.
IMPORTANT: The release bearing is packed with grease and may not be washed in solvent.
4. Check the release bearing for excessive play and for minimal bearing drag. Replace bearing if excessive play or no/little drag is found.
5. Use a feeler gauge to measure the distance between clutch housing cover assembly (pressure plate) and flywheel surfaces to determine clutch disc facing thickness. Replace disc if not within specification.
Thickness Range:
4.65 mm - 7.10 mm (0.18 - 0.28 inch)
6. Remove clutch housing cover assembly (pressure plate) to flywheel bolts.
NOTICE: Remove bolts in a progressive crisscross pattern to prevent warping of the cover stamping.
7. Remove clutch housing cover assembly and clutch disc.
IMPORTANT: Black random spotting on friction surface of clutch housing cover assembly (pressure plate) is normal.
8. Inspect clutch housing cover assembly surface for excessive wear, chatter marks, cracks or overheating (indicated by blue discoloration). Replace clutch housing cover assembly if damaged.
9. Check for clutch housing cover assembly warpage using a straight edge and feeler gauge.
Maximum Warpage: 0.15 mm (0.006 inch)
10. Check clutch disc facings for oil or burnt spots. Replace clutch disk if necessary.
11. Check disc for loose damper springs, hub, or rivets. Replace disc if any are broken or excessively loose.
12. Inspect the flywheel ring gear for wear or damage. Replace flywheel if damaged.
IMPORTANT: Black random spotting on friction surface of flywheel is normal.
13. Check flywheel to clutch disc contact surface for wear, cracks, chatter marks, or overheating (indicated by blue discoloration). Repair or replace flywheel if necessary.
Minimum Flywheel Thickness: 28 mm (1.102 inch)
14. Measure flywheel runout using a dial indicator for at least two revolutions. Measure the runout at a diameter just inside the clutch housing cover (pressure plate) bolt holes. Push the crankshaft forward to take up thrust bearing clearance. Repair or replace flywheel if not within specification.
Maximum Runout: 0.15 mm (0.006 inch)
15. Check the flywheel for warpage using a straight edge and feeler gauge.
Maximum Warpage: 0.15 mm (0.006 inch)
16. Remove flywheel-to-crankshaft bolts and remove flywheel.
INSTALLATION
1. Install flywheel-to-crankshaft and start bolts.
2. Torque the bolts in a crisscross pattern.
- Torque: 80 Nm (59 ft. lbs.)
3. Install the clutch disc alignment tool SA9145T in the clutch disc and push in until it bottoms out in the crankshaft.
NOTICE: If disc is being replaced, clutch housing cover must be re-adjusted prior to installation. Refer to "Clutch Housing Cover Re-Adjustment" procedure. Clutch Housing Cover Re-Adjustment Procedure
4. Install clutch disc and clutch housing cover assembly (pressure plate) with purple dot on clutch housing cover assembly aligned as close as possible to the mark on flywheel. Position clutch disc so that the side marked "FLYWHEEL SIDE" is toward flywheel. Start clutch housing cover assembly to flywheel bolts.
IMPORTANT: When tightening the clutch housing cover assembly bolts, do not tighten any one bolt more than half a turn at a time or the clutch housing cover assembly may warp.
5. Tighten clutch housing cover assembly bolts using a progressive crisscross pattern to prevent warping of the cover stamping.
- Torque: 25 Nm (18 ft. lbs.)
6. Remove clutch alignment tool from clutch disc.
7. Install clutch fork stabilizer and ball stud if removed.
- Torque: 24 Nm (18 ft. lbs.)
8. Install fork retainer to clutch fork.
NOTICE: Do not lube the release bearing or bearing quill.
9. Install release fork and bearing to transaxle by snapping fork onto ball stud.
10. Lube fork pivot point with clutch spline lubricant (P/N 21005995) or equivalent and install release bearing to release fork.
IMPORTANT: Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.
11. Lightly lube input shaft splines with clutch spline lubricant (P/N 21005995) or equivalent.
NOTICE: The release bearing may be off-centered initially. It will correct itself once the clutch is engaged and should not be considered a damaged/faulty component.
12. Install transaxle.