Clutch Disc: Service and Repair

Clutch Replacement

Special Tools Required

- Pressure Plate Compressor 07AAE-P8EA000
- 3.5 Engine Clutch Compressor Adapters 07AAE-P8EA220
- Clutch Alignment Shaft 07AAF-P8EA000
- Pressure Plate Compressor Adapter 07AAK-P8EA000
- Ring Gear Holder 07LAB-PV00100
- Bearing Driver Attachment, 37 x 40 mm 07746-0010200
- Driver Handle, 15 x 135L 07749-0010000

Engine Side

NOTICE
You must use the pressure plate compressor, the 3.5 engine clutch compressor adapters, the clutch alignment shaft, and the pressure plate compressor adapter to remove and install the clutch pressure plate or you will damage it.


Pressure Plate Inspection and Removal

1. Remove the transmission Manual Transmission Removal.

2. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment shaft, the pressure plate compressor adapter (A), and a feeler gauge (B). If the height difference is more than the service limit, replace the pressure plate and the clutch disc as a set.










3. Install the clutch alignment shaft, the pressure plate compressor adapter (A), the pressure plate compressor (B), and the 3.5 engine clutch compressor adapters (C).





4. Turn the center screw (D) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.

5. Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.





6. Turn the center screw (B) on the pressure plate compressor counterclockwise by hand to release the pressure, then install two pressure plate mounting bolts by finger-tight to hold the pressure plate (C).

7. Remove the pressure plate compressor, the pressure plate compressor adapter, and the clutch compressor adapters, then remove the finger-tightened bolts and the pressure plate.

8. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.






9. Inspect the pressure plate surface (A) for wear, cracks, and burning.






10. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the any measured point is more than the service limit, replace the pressure plate and the clutch disc as a set.










Clutch Disc Inspection and Removal

11. Remove the clutch disc (A) and the clutch alignment shaft (B).





12. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc and the pressure plate as a set. If the clutch disc is oil soaked, find and repair the source of the oil leak.

13. Measure the clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc and the pressure plate as a set.










14. 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 and the pressure plate as a set.










Flywheel Inspection

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 with pushing against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within the standard, replace the flywheel, and recheck the runout; then go to step 19.










Pilot Bearing Inspection

18. Turn the inner race of the pilot bearing with your finger. The pilot bearing should turn smoothly and quietly. Check that 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. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder. Do not use impact tools to tighten the flywheel bolts. Using impact tools may permanently damage the flywheel.

21. Remove the pilot bearing (A) from the flywheel (B).






22. Install a new pilot bearing (A) into the flywheel using the 15 x 135L driver handle (B) and the 37 x 40 mm bearing driver attachment (C). Apply a light coat of oil to the bearing outer surface.





23. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.

24. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps. Do not use impact tools to tighten the flywheel bolts. Using impact tools may permanently damage the flywheel.





25. Remove the ring gear holder.

Clutch Disc and Pressure Plate Installation

NOTE: The clutch disc and the pressure plate are a matched set and must be replaced together.

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

27. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the pilot bearing (A).





28. 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 clutch alignment shaft (D).

29. Align the point marks (A) across the pressure plate (B) and the flywheel (C).





30. Install the pressure plate and the mounting bolts (D) finger-tight.

31. Install the pressure plate compressor adapter (A), the 3.5 engine clutch compressor adapters (B), and the pressure plate compressor (C).





32. Turn the center screw (D) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.

33. Be careful not to damage the pressure plate (E). Tighten (180 degrees apart) the pressure plate mounting bolts (F) in the pattern as shown in several steps.






34. Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure, then remove the pressure plate compressor (A), the pressure plate compressor adapter (B), the clutch alignment shaft, and the clutch compressor adapters (C).





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

36. Do the release bearing inspection, and replace it if necessary.

37. Install the transmission Manual Transmission Installation.

Transmission Side

Release Bearing Removal

1. Remove the transmission Manual Transmission Removal.

2. Remove the release fork boot (A) from the clutch housing (B).





3. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D). Remove the release bearing (E).

Release Bearing Inspection

4. 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.






Release Bearing Installation

5. 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, then set the release fork set spring (E).

NOTE: Replace the release fork bolt if necessary.






6. With the release fork (A) slide between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole (C) in the clutch housing.





7. Align the detent (D) of the release fork with the release fork bolt (E), then press the detent of the release fork over the release fork bolt squarely.

8. Install the release fork boot (F). Make sure the boot seals around the release fork and the clutch housing.

9. 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. Wipe off any excess grease.





10. Install the transmission Manual Transmission Installation.