Clutch Disc: Service and Repair
CLUTCH DISC AND CLUTCH COVERCL-19 Exploded View:
CAUTION:
^ If transmission assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder) body and CSC tube. Return CSC body insert to original position to remove transmission assembly. Dust on clutch disc sliding parts may damage seal of CSC body and may cause clutch fluid leakage.
^ Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
^ When installing, be careful that grease applied to main drive gear does not adhere to clutch disc.
^ Never clean in solvent on clutch disc.
^ If flywheel is removed, align dowel pin with the smallest hole of flywheel.
Removal and Installation
CAUTION:
If transmission assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder) body and CSC tube. Return CSC body insert to original position to remove transmission assembly. Dust on clutch disc sliding parts may damage seal of CSC body and may cause clutch fluid leakage.
REMOVAL
1. Remove transmission assembly from the vehicle.
2. Loosen clutch cover mounting bolts with power tool.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and main drive gear splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and main drive gear splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of CSC body, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the parts.
3. Install clutch disc using the clutch aligning bar [SST: ST20670000 ( - )]
CAUTION:
If either clutch disc or clutch cover is needed to be replaced, replace them as a set.
4. Install clutch cover. Pre-tighten clutch cover mounting bolts.
CAUTION:
If either clutch disc or clutch cover is needed to be replaced, replace them as a set.
5. Tighten clutch cover mounting bolts evenly in two steps in the order shown in the figure.
6. Install transmission assembly to the vehicle.
Inspection
INSPECTION AFTER REMOVAL
CLUTCH DISC
^ Measure circumferential runout relative to clutch disc center spline. If it is outside the specification, replace clutch disc and clutch cover as a set.
Runout limit/diameter of the area to be measured: Refer to CL-22, "Clutch Disc". Clutch Disc
^ Measure backlash to clutch disc spline and main drive gear spline at the circumference of clutch disc. If outside the specification, replace clutch disc and clutch cover as a set.
Maximum allowable spline backlash (at outer edge of disc): Refer to CL-22, "Clutch Disc". Clutch Disc
^ Measure the depth "A" to clutch disc facing rivet heads using calipers. If it exceeds the allowable wear limit, replace clutch disc and clutch cover as a set.
Facing wear limit (depth to the rivet head): Refer to CL-22, "Clutch Disc". Clutch Disc
CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height using the diaphragm adjusting wrench [SST: ST20050240 ( - )].
Tolerance for diaphragm spring lever unevenness: Refer to CL-22, "Clutch Cover". Clutch Cover
^ Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch disc and clutch cover as a set.
NOTE:
^ Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
^ Broken thrust ring will make a clinking sound when cover is shaken up and down.
^ If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, repair the surface with sandpaper. If surface is damaged or distorted, replace clutch disc and clutch cover as a set.