Pressure Plate: Service and Repair
Clutch Disc and CoverREMOVAL
NOTE: The illustration below is for Turbo model. However, perform the same procedure for Non-turbo model.
1. Remove the transmission assembly from vehicle.
2. Insert the ST on flywheel.
ST 499747100 CLUTCH DISC GUIDE
3. Remove the clutch cover and clutch disc.
NOTE:
^ Take care not to allow oil on the clutch disc surface.
^ Do not disassemble the clutch cover or clutch disc.
^ Be sure to mark alignment marks on the flywheel and clutch cover before removing clutch cover.
INSTALLATION
NOTE: The illustration below is for Turbo model. However, perform the same procedure for Non-turbo model.
1. Insert the ST into clutch disc and install on the flywheel by inserting the ST end into pilot bearing.
NOTE: When installing the clutch disc, be careful of its direction.
ST 499747100 CLUTCH DISC GUIDE
2. Place the clutch cover on flywheel and tighten the bolts to specified torque.
NOTE:
^ When reinstalling, align the alignment marks.
^ When installing a new clutch cover and flywheel, position the clutch cover in order to make the gap between 0 marks of flywheel and clutch cover 120° or more.
^ Note the front and rear of the clutch disc when installing.
^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order.
Tightening torque: 16 Nm (1.6 kgf-cm, 11.8 ft. lbs.)
3. Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4. Install the transmission assembly.
INSPECTION
NOTE: The illustration below is for Non-turbo model. However, perform the same procedure for Turbo model.
CLUTCH DISC
1. Facing wear: Measure the depth from the surface of facing to rivet head. 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)
NOTE: Do not wash the clutch disc with any cleaning fluid.
2. Hardened facing: Replace the clutch disc.
3. Oil leakage on facing: Replace the clutch disc and inspect the 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, replace the clutch disc.
ST 499747100 CLUTCH DISC GUIDE
Limit for deflection:
Turbo model 1.0 mm (0.039 inch) at R = 110 mm (4.33 inch)
Non-turbo model 0.7 mm (0.027in) at R= 110mm (4.33 inch)
5. If the spline wears, rivets loosen and damper spring is failure, replace the clutch disc.
CLUTCH COVER
NOTE: Visually check 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 installation area
5. Worn diaphragm sliding area