Clutch Disc: Service and Repair
Clutch Replacement
Pressure Plate Removal and Inspection
1. Remove the transmission. Manual Transmission Removal
2. Check the height-variation of the diaphragm spring fingers using the dial indicator (A). If the variation exceeds the service limit, replace the pressure plate.
3. Install the ring gear holder (A), the clutch alignment shaft (B), and the remover handle (C).
4. To prevent warping, remove the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
5. Remove the release bearing (F) from the pressure plate.
6. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
7. Inspect the pressure plate surface (B) for wear, cracks, and burning.
8. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the warpage exceeds the service limit, replace the pressure plate.
Release Bearing Inspection
9. Check the play of the release bearing by spinning it by hand, if there is excessive play or noise, replace the release bearing.
NOTE: The release bearing is packed with grease. Do not wash it in solvent.
Clutch Disc Removal and Inspection
10. Remove the clutch disc (A), the clutch alignment shaft (B), and the remover handle (C).
11. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is soaked with oil, replace it and the pressure plate as a set. If the clutch disc is oil soaked, find and repair the source of the oil leak.
12. Measure the clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc.
13. Measure the depths of the rivets from the clutch disc lining surface (A) to the rivets (B), on both sides. If the measurement is less than the service limit, replace the clutch disc.
Flywheel and Pilot Bearing Inspection
14. Remove the ring gear holder.
15. Inspect the ring gear teeth for wear and damage.
16. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
17. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns while pushing against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement exceeds the service limit, replace the flywheel, and recheck the runout, then go to step 19.
18. Turn the inner race of the pilot bearing (A) with your finger. The pilot bearing should turn smoothly and quietly. Make sure the pilot bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the pilot bearing, then go to step 19.
Flywheel and Pilot Bearing Replacement
19. Install the ring gear holder (A).
20. Remove the flywheel mounting bolts (B) in a crisscross pattern in several steps, then remove the flywheel and the ring gear holder.
21. Remove the pilot bearing (A) from the flywheel (B).
22. Install a new pilot bearing into the flywheel using the 32 x 37 mm bearing driver attachment (A) and the 15 x 135L driver handle (B) as shown. Apply a light coat of engine oil to the bearing surface.
23. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and the mounting bolts, finger-tight.
24. Install the ring gear holder (A), then torque the flywheel mounting bolts in a crisscross pattern in several steps.
Clutch Disc and Pressure Plate Installation
25. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B).Temporary install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft, and remove extra overflow grease.
26. Install the ring gear holder (C).
27. Install the clutch disc using the clutch alignment shaft (D) and the remover handle (E).
28. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B). Temporary install the release bearing onto the release bearing guide. Make sure the release bearing slides freely on the release bearing guide, and remove extra overflow grease. Then install the release bearing on the pressure plate (C).
29. Install the pressure plate and the mounting bolts (D), finger-tight. Make sure the release bearing does not come off.
30. Torque the mounting bolts in a crisscross pattern in several steps to prevent warping the diaphragm spring.
31. Remove the ring gear holder, the clutch alignment shaft, and the remover handle.
32. Make sure the diaphragm spring fingers are all the same height.
33. Install the transmission. Manual Transmission Installation
