Clutch: Service and Repair
CLUTCH UNIT (MTM)
COMPONENTS
OVERHAUL
1. REMOVE MANUAL TRANSAXLE ASSY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork with the clutch release bearing from the transaxle assy.
3. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing assy from the clutch release fork.
4. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the transaxle assy.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE CLUTCH RELEASE FORK BOOT
7. REMOVE CLUTCH COVER ASSY
a. Put matchmarks on the clutch cover assy and the flywheel sub-assy.
b. Loosen each set bolt one turn at a time until spring tension is released.
c. Remove the set bolts, and pull off the clutch cover assy.
NOTICE: Do not drop the clutch disc assy.
8. REMOVE CLUTCH DISC ASSY
NOTICE: Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub-assy away from oil and foreign matter.
9. INSPECT CLUTCH DISC ASSY
a. Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc assy.
b. Install the clutch disc assy to the transaxle assy.
NOTICE: Take care not to insert the clutch disc assy in the wrong direction.
c. Using a dial indicator, check the clutch disc assy runout.
Maximum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc assy.
10. INSPECT CLUTCH COVER ASSY
a. Using vernier calipers, inspect the diaphragm spring for the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 inch)
B (Width): 6.0 mm (0.236 inch)
If necessary, replace clutch cover assy.
11. INSPECT FLYWHEEL SUB-ASSY
a. Using a dial indicator, inspect the flywheel sub-assy runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assy.
12. INSPECT CLUTCH RELEASE BEARING ASSY
a. Check that the clutch release bearing assy moves smoothly without abnormal resistance by turning the sliding parts of the clutch release bearing assy (contact surfaces with the clutch cover) while applying force in the axial direction.
b. Inspect the clutch release bearing assy for damage or wear.
HINT: Replace the release bearing assy an necessary.
13. INSTALL CLUTCH DISC ASSY
a. Insert SST in the clutch disc assy, then insert them in the flywheel sub-assy.
SST 09301-00210
NOTICE: Take care not to insert the clutch disc assy in the wrong direction.
14. INSTALL CLUTCH COVER ASSY
a. Align matchmarks on the clutch cover assy and flywheel sub-assy.
b. Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting from the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
HINT:
^ Evenly tighten the bolts by following the order shown in the illustration.
^ Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.
15. INSPECT AND ADJUST CLUTCH COVER ASSY
a. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If alignment is not as specified, adjust the diaphragm spring tip alignment using SST
SST 09333-00013
16. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle assy.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
17. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Apply release hub grease to the contact surfaces of, the release fork and release bearing assy, release fork and push rod, and release fork and fork support.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Install the release fork to the release bearing assy.
c. Install the release bearing hub clip.
18. INSTALL CLUTCH RELEASE BEARING ASSY
a. Apply the clutch spline grease to the input shaft spline.
Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
b. Install the clutch release bearing w/ release fork to the transaxle assy.
NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly.
19. INSTALL CLUTCH RELEASE FORK BOOT
20. INSTALL MANUAL TRANSAXLE ASSY