Clutch: Service and Repair

Clutch Replacement

Special Tools Required
- Clutch alignment shaft 07JAF-PM7012A
- Remover handle 07936-3710100
- Ring gear holder 07LAB-PV00100 or 07924-PD20003
- Driver 07749-0010000
- Attachment, 32 x 35 mm 07746-0010100

Pressure Plate and Clutch Disc Removal





1. Check the diaphragm spring fingers for height using the dial indicator (A). If the height is more than the service limit, replace the pressure plate.





2. Install the special tools.
3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).





4. Inspect the pressure plate (A) surface for wear, cracks, and burning.
5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area.





6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.





7. Remove the clutch disc and special tools.
8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it.





9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.





10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the runout is more than the service limit, replace the flywheel and recheck the runout.

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.





3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Resurfacing the flywheel is not recommended.





4. Turn the inner race of the ball bearing (A) with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing.

Flywheel Replacement





1. Install the special tool.
2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.





3. Remove the sensor disc.





4. Remove the ball bearing (A) from the flywheel (B).





5. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface.





6. Install the sensor disc.





7. Align the hole (A) in the flywheel with the crankshaft dowel pin (B), and install the flywheel (C). Install the mounting bolts finger-tight.





8. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.

Clutch Disc and Pressure Plate Installation

1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.





2. Install the special tool (A).
3. Apply Super High Temp Urea Grease (P/N 08798-9002) to the splines (B) of the clutch disc (C), then install the clutch disc using the special tools.





4. Install the pressure plate (A) and the mounting bolts (B), finger-tight.





5. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.

Pressure Plate Mounting Bolt Torque:
25 Nm (2.6 kgf-m, 19 lbf-ft)

6. Remove the special tools.

7. Make sure the diaphragm spring fingers are all the same height.


Release Bearing Replacement





1. Remove the release fork boot (A) from the clutch housing (B).
2. Remove the release fork (c) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).





3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one.

NOTE: The release bearing is packed with grease. Do not wash it in solvent.





4. Apply Super High Temp Urea Grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.
5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.
6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely.
7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing.





8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly.