Flywheel: Service and Repair
Clutch ReplacementSpecial Tools Required
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Clutch alignment shaft 07LAF-PT001 10
^ Attachment, 32 x 37 mm 07746-0010200
^ Driver 07749-0010000
^ Remover handle 07936-3710100
Pressure Plate and Clutch Disc Removal
1. Check the height-variation of the diaphragm spring fingers using the dial indicator (A). If the variation 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. Remove the release bearing (C) from the pressure plate.
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
6. Inspect the surface of the pressure plate for wear, cracks, and burning.
7. 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.
8. Remove the clutch disc and special tools.
9. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch looks burnt or is oil soaked, replace it. Find and repair the source of the oil leak it the clutch disc is soaked.
10. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.
11. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B), on both sides. If the rivet depth is less than the service limit, replace the clutch disc.
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 with the 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 ball bearing (A) from the flywheel (B).
4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface.
5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts, finger-tight.
6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.
Release Bearing Inspection
Check the play of the release bearing by spinning it with your 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.
Clutch Disc and Pressure Plate Installation
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
2. Install the ring gear holder.
3. Install the clutch disc using the special tools.
4. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B), then install the release bearing on the pressure plate (C).
5. Install the pressure plate and the mounting bolts (D), finger-tight. Make sure the release bearing does not come off.
6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.
7. Remove the special tools.
8. Make sure the diaphragm spring fingers are all the same height.