Clutch Replacement

1. Remove transaxle as described under Manual Transmission/Transaxle.
2. Remove release bearing as follows:
a. Remove boot from clutch housing.
b. Remove release fork from clutch housing by squeezing release fork set spring with pliers.
3. Check release bearing for excessive play and roughness, then replace if necessary.
4. Measure diaphragm spring fingers height using special clutch alignment disc and shaft tool Nos. 07JAF-PM7001A, 07JAF-PM7012A and 07936-3710100, or equivalents. Standard is 0.03 inches.
5. If height exceeds 0.04 inch, replace pressure plate.
6. Lock flywheel with a special ring gear holder tool No. 07LAB-PV00100, or equivalent, then install special clutch alignment shaft tool Nos. 07JAF-PM7012A and 07936-3710100, or equivalents.
7. Loosen pressure plate attaching bolts in crisscross pattern, one turn at a time to prevent warping pressure plate, then remove pressure plate.
8. Inspect pressure plate surface for wear, cracks and burning, then check warpage. Standard new warpage is 0.001 inches.
9. If pressure plate warpage exceeds 0.006 inch, replace.
10. Remove clutch disc from flywheel and special tools.
11. Inspect clutch lining for signs of slippage and oil, replace if burned black or oil soaked.
12. Measure clutch disc thickness. Standard new is 0.33-0.36 inches; service limit is 0.24 inches.
13. Measure depth from lining surface to rivets on both sides. Standard new is 0.05 inches; service limit is 0.01 inches.
14. Spin release bearing by hand and check for excessive play. Do not wash bearing in solvent.
15. Inspect flywheel teeth for wear and damage, then check mating surface for wear, cracks and burning.
16. Inspect flywheel runout as follows:
a. Using a dial indicator, measure flywheel runout through a minimum of two full turns.
b. Push against flywheel while turning to eliminate thrust washer clearance.
c. Standard runout new is 0.002 inches; service limit is 0.006 inches.
d. Turn inner ball bearing race with your finger. Replace if inner race does not turn smoothly, quietly and fit tightly.
e. To remove bearing, install ring gear holder special tool No. 07LAB-PV00100, or equivalent, and remove flywheel mounting bolts in a crisscross pattern in several steps.
f. Remove flywheel and drive bearing out with drift punch, then drive new bearing in with special tool No. 07746-0.010100, or equivalent.
g. Align flywheel hole with crankshaft dowel pin and install bolts finger tight.
h. Install ring gear holder and torque bolts to 87 ft. lbs. in several steps in crisscross pattern.
17. Install ring gear holder, apply grease to clutch disc splines and install using special clutch alignment tool Nos. 07396-3710100 and 07JAF-PM7012A, or equivalents.
18. Install pressure plate, then torque pressure plate mounting bolts two turns at a time, in crisscross pattern, to 19 ft. lbs.