Clutch: Service and Repair

Clutch Disc and Cover

REMOVAL
1) Remove the transmission assembly from the vehicle.
2) Attach the ST on the flywheel.
ST 499747100 CLUTCH DISC GUIDE





3) Remove the clutch cover and clutch disc.

NOTE:
^ Take care not to allow oil to touch the clutch disc face.
^ Do not disassemble the clutch cover or clutch disc.

INSTALLATION
1) Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing.

NOTE:
When installing the clutch disc, be careful to attach in the correct direction.

ST 499747100 CLUTCH DISC GUIDE





2) Install the clutch cover to the flywheel and tighten the bolts to the specified torque.

NOTE:
^ When installing a clutch cover to the flywheel, position the clutch cover so that the spacing between the unbalance marks (paint mark) on the flywheel and clutch cover is 120° or more apart. (The unbalance mark indicates the direction of residual unbalance.)
^ Note the front and rear of the clutch disc when installing.
^ Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross order.





3) Remove the ST.
4) Install the transmission assembly.

INSPECTION

CLUTCH DISC
1) Facing wear
Measure the depth from the facing surface to the rivet head. Replace if the face is worn locally or worn down to less than the specified value.

NOTE:
Do not wash the clutch disc with any type of cleaning fluid.





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





4) Deflection on facing
If deflection exceeds the specified value at the outer circumference of the facing, replace the clutch disc.
Limit for deflection:
0.7 mm (0.028 in) at R = 110 mm (4.33 in)
ST 499747100 CLUTCH DISC GUIDE





5) If there is spline wear, loose rivets, failed damper springs, etc., 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 the pressure plate
4) Loose strap plate installation area
5) Worn diaphragm sliding area