Clutch: Service and Repair
Clutch Replacement
Special Tools Required
- Clutch Alignment Disc 07JAF-PM7011A
- Clutch Alignment Shaft 07JAF-PM7012A
- Clutch Alignment Shaft 07ZAF-PR8A100
- Ring Gear Holder 07LAB-PV00100
- Weight, Remover 07741-0010201
- Driver Handle, 15 x 135L 07749-0010000
- Remover Handle 07936-3710100
- Bearing Remover Shaft Set, 15 mm 07936-KC10500
- Bearing Driver Attachment, 28 x 30 mm 07946-1870100
Engine Side
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 disc (A), clutch alignment shaft (B), remover handle (C), and a feeler gauge (D). If the height difference is more than the service limit, replace the pressure plate.
3. Install the ring gear holder (A), the remover handle (B), and the clutch alignment shaft (C).
4. To prevent warping, unscrew the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
6. Inspect the pressure plate (A) surface for wear, cracks, and burning.
7. Inspect for warpage using a precision straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the measurement is greater than the service limit, replace the pressure plate.
Clutch Disc Inspection and Removal
8. Remove the clutch disc (A), the remover handle (B), and the clutch alignment shaft (C).
9. Inspect the lining of the clutch disc for signs of slipping 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.
10. Measure the clutch disc thickness. If the measurement 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 measurement is less than the service limit, replace the clutch disc.
Flywheel Inspection
12. Remove the ring gear holder.
13. Inspect the ring gear teeth for wear and damage.
14. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
15. 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 more than the service limit, replace the flywheel, and recheck the runout. Go to step 16.
Flywheel Replacement
16. Install the ring gear holder.
17. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder.
18. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
19. Install the ring gear holder (A), then tighten the flywheel mounting bolts (B) in a crisscross pattern in several steps.
Pilot Bearing Inspection
20. Inspect the crankshaft pilot bearing for wear and damage.
21. Inspect the inside surface of the crankshaft pilot bearing with your finger. If the crankshaft pilot bearing is not smooth, replace it; go to step 22.
Pilot Bearing Replacement
22. Remove the crankshaft pilot bearing (A) using the remover weight (B), and the 15 mm bearing remover shaft set (C).
23. Install a new pilot bearing (A) into the crankshaft using the 15 x 135L driver handle (B) and the 28 x 30 mm bearing driver attachment (C).
Clutch Disc and Pressure Plate Installation
24. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
25. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bearing (A).
26. 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 remover handle (D) and the clutch alignment shaft (E).
NOTE: Wipe off any excess grease.
27. Install the pressure plate (A) and the mounting bolts (B) finger-tight.
28. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.
29. Remove the ring gear holder (A), the remover handle, and the clutch alignment shaft (B).
30. Make sure the diaphragm spring fingers are all the same height.
31. Do the release bearing inspection, and replace it if necessary.
32. 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. Squeeze the release fork set spring (C) with pliers to remove the release fork (D) from the clutch housing. 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 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) slid 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 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.
NOTE: Wipe off any excess grease.
10. Install the transmission Manual Transmission Installation.