Clutch
Components Removal / installation
CLUTCH
CLUTCH
EXPLODED VIEW
REMOVAL
1. Removal of manual transmission ASSY (refer to 
)
)
2. Removal of clutch release fork SUB-ASSY
(1) Remove the clutch release fork SUB-ASSY and the release fork support.
(2) Remove the clutch release fork SUB-ASSY and the clutch release bearing ASSY from the manual transmission ASSY.
3. Removal of clutch release bearing ASSY
(1) Remove 2 release bearing hub clips to remove the clutch release bearing ASSY.
4. Removal of release bearing hub clip
(1) Remove 3 release bearing hub clips from the clutch release bearing ASSY.
5. Removal of clutch release fork boot
(1) Remove the clutch release fork boot from the manual transmission ASSY.
6. Removal of release fork support
(1) Remove the release fork support from the manual transmission ASSY.
7. Removal of clutch cover ASSY
8. Removal of clutch disc ASSY
CAUTION:
Keep oil and foreign substances away from the lining area, pressure plate, and flywheel clutch disc sliding area of the clutch disc ASSY.
INSPECTION
1. Check of clutch disc ASSY
(1) Use a caliper gauge to check the wear of the facing.
Captions in illustration
| *1 |
Facing |
| *2 |
Rivet |
Limit
: 0.3 mm {0.012 in} (rivet sinking volume)
NOTE:
Replace the clutch disc ASSY if below the limit.
(2) Using a dial gauge and the SST, check the deflection of the clutch disc ASSY by turning it.
SST
499747100
Limit
: 0.7 mm {0.028in}
NOTE:
Replace the clutch disc ASSY if above the limit.
2. Check of clutch cover ASSY
(1) Visually check the following items, and if any malfunction is found, replace the clutch cover ASSY.
1. Loose thrust rivet
2. Damaged or worn bearing contact area at the center of diaphragm spring
3. Damaged or worn disc contact surface of the pressure plate
4. Loose strap plate installation area
5. Worn diaphragm spring sliding area
2. Damaged or worn bearing contact area at the center of diaphragm spring
Captions in illustration
| *1 |
Thrust rivet |
| *2 |
Diaphragm spring |
3. Damaged or worn disc contact surface of the pressure plate4. Loose strap plate installation area
5. Worn diaphragm spring sliding area
Captions in illustration
| *1 |
Pressure plate |
| *2 |
Strap plate |
3. Check of flywheel SUB-ASSY
(1) Check for damage and wear at the facing sliding area and the ring gear.
Captions in illustration
| *1 |
Flywheel SUB-ASSY |
| *2 |
Ring gear |
NOTE:
If defective, replace the flywheel SUB-ASSY.
(2) Check for rotation stuck, noise, and excessive play by rotating while applying pressure in the thrust direction.
NOTE:
If defective, replace the flywheel SUB-ASSY.
4. Check of clutch release bearing ASSY
(1) Check for rotation stuck and noise by rotating while applying pressure in the thrust direction.
CAUTION:
Do not wash the clutch release bearing ASSY since it is filled with grease.
NOTE:
If any stuck or noise is observed, replace the clutch release bearing ASSY.
INSTALLATION
1. Installation of clutch disc ASSY
2. Installation of clutch cover ASSY
(1) Match the alignment marks of the clutch cover ASSY and the flywheel and install the clutch cover ASSY.
NOTE:
When replacing the flywheel or the clutch cover with a new one, position the clutch cover so that the angle formed by the imbalance marks (paint marks) on the flywheel and clutch cover becomes 120 ° or more. (The imbalance marks indicate the direction of residual imbalance.)
Captions in illustration
| *a |
Alignment marks |
| *b |
Imbalance mark (paint mark) |
(2) Lightly tighten the bolts from the upper one near the flywheel knock pin and equally tighten the 6 bolts in the order shown in the figure after checking that the clutch disc ASSY is positioned at the center by lightly shaking the SST from side to side and up and down.
Standard value:
SST
499747100
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
CAUTION:
Equally tighten the bolts in several times.
(3) Remove the SST.
3. Installation of release fork support
(1) Install the release fork support to the manual transmission ASSY.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
4. Installation of clutch release fork boot
(1) Install the clutch release fork boot to the manual transmission ASSY.
5. Installation of release bearing hub clip.
(1) Install 3 release bearing hub clips to the clutch release bearing ASSY.
6. Installation of clutch release fork SUB-ASSY
(1) Apply NICHIMOLY N-130 or equivalent to the points of the clutch release fork SUB-ASSY shown in the figure.
Captions in illustration
 |
NICHIMOLY N-130 or equivalent |
NOTE:
·Contacting surface to release fork support
·Contacting surface to release cylinder push rod
·Contacting surface to release bearing hub
·Contacting surface to release cylinder push rod
·Contacting surface to release bearing hub
(2) Install the clutch release fork SUB-ASSY to the clutch release bearing ASSY.
7. Installation of clutch release bearing ASSY
(1) Apply NICHIMOLY N-130 or equivalent to the input shaft spline area of the manual transmission ASSY.
Captions in illustration
|
|
NICHIMOLY N-130 or equivalent |
CAUTION:
Do not apply NICHIMOLY N-130 or equivalent to area A shown in the figure.
(2) Install the clutch release bearing ASSY and the clutch release fork SUB-ASSY to the manual transmission ASSY.
CAUTION:
After installation, make sure the clutch release bearing ASSY slides smoothly by moving the clutch release fork SUB-ASSY backward and forward.
8. Installation of manual transmission ASSY (refer to )
)