Initial Inspection and Diagnostic Overview

INSPECTION

1. CLUTCH DISC





1. Facing wear:
Measure the depth of rivet head from the surface of facing. Replace if the facings are worn locally or worn down to less than the specified value.
Depth of rivet head:
Limit of sinking 0.3 mm (0.012 inch)

CAUTION: Do not wash the clutch disc with any cleaning fluid.

2. Hardened facing: Correct by using emery paper or replace.





3. Oil soakage on facing: Replace the clutch disc and inspect transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.





4. Deflection on facing: If deflection exceeds the specified value at the outer circumference of facing, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
Limit for deflection:
Non-turbo model: 1.0 mm (0.039 inch) at R = 107 mm (4.21 inch)
Turbo model: 0.8 mm (0.031 inch) at R = 110 mm (4.33 inch)





5. Worn spline, loose rivets and torsion spring failure: Replace defective parts.


2. CLUTCH COVER

NOTE: Visually check for the following items without disassembling, and replace or repair if defective.

1. Loose thrust rivet.





2. Damaged or worn bearing contact area at the center of diaphragm spring.
3. Damaged or worn disc contact surface of pressure plate.
4. Loose strap plate setting bolt.





5. Worn diaphragm sliding surface.