Clutch: Service and Repair

Clutch Disc
INSPECTION
Check the following items, and replace if necessary.
^ Clutch disc, for burns, discoloration, oil or grease leakage





^ Clutch disc, for wear of facing
Wear limit of facing surface to rivet head: Model 190, 215 0.3 mm (0.012 inch)





^ Clutch disc, for backlash of spline and runout of facing
Maximum backlash of spline (at outer edge of disc):
Model 190 0.8 mm (0.031 inch)
Model 215 0.9 mm (0.035 inch)
Runout limit:
Model 190, 215 1.0 mm (0.039 inch)
Distance of runout check point (from hub center):
Model 190 90 mm (3.54 inch)
Model 215 102.5 mm (4.04 inch)

INSTALLATION
^ Apply recommended grease to contact surface of splines.
^ Too much lubricant may damage clutch disc facing.

Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT





^ Check clutch cover while installed on vehicle for uneven diaphragm spring toe height.
Uneven limit: Model 190, 215 0.7 mm (0.028 inch)
If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.





^ Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.
^ Check flywheel runout.
Maximum allowable runout: Refer to Flywheel, M/T; Specifications.

INSTALLATION





^ Insert Tool into clutch disc hub when installing clutch cover and disc.
^ Be careful not to allow grease to contaminate clutch facing.
^ Tighten bolts in numerical order, in two steps.
First step: R: 10 - 20 Nm (1.0 - 2.0 kg.m, 7.2 - 14 ft. lbs.)
Final step: R: 22 - 29 Nm (2.2 - 3.0 kg.m, 16 - 22 ft. lbs.)