Clutch Disc: Service and Repair

REMOVAL
1. Remove transmission.

Fig. 3:

2. Remove clutch inspection cover (4) screws.

Fig. 4:

3. Remove bell housing bolts (6). Remove bell housing from engine.
4. Mark clutch cover (pressure plate) and flywheel to maintain their same relative positions when reinstalling clutch assembly.
5. Insert Clutch Disc Aligning Tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings.
6. Loosen clutch cover (pressure plate) attaching bolts, one or two turns at a time, in a crisscross pattern. This will release spring pressure evenly and avoid clutch cover damage.
7. Remove the clutch cover (pressure plate) assembly and disc from flywheel. Handle carefully to avoid contaminating the friction surfaces.

INSPECTION AND INSTALLATION
1. Inspect for oil leakage through engine rear main bearing oil seal and transmission input shaft. If leakage is noted, it should be corrected at this time.
2. Inspect the friction faces of the flywheel and clutch cover (pressure plate) for:
- Excessive discoloration
- Burned areas
- Small cracks
- Deep grooves
- Ridges
3. Replace parts as required.
4. Clean the flywheel face with crocus cloth or fine sandpaper (400 - 600 grade), then wipe the surface with mineral spirits. If the surface is severely scored, heat checked, or warped, replace the flywheel.

CAUTION: Do not machine the flywheel face. If flywheel surface is bad the flywheel must be replaced.

5. If the flywheel is to be replaced or removed apply thread sealer to the flywheel retaining bolts when installing. This will prevent engine oil from leaking onto the clutch.
6. The disc assembly should be handled without touching the facings. Replace disc if the facings show evidence of grease or oil soakage, or wear to within less than 0.38 mm (0.015 inch) of the rivet heads. The splines on the disc hub and transaxle input shaft should be a snug fit without signs of excessive wear. Metallic portions of disc assembly should be dry and clean, and not been discolored from excessive heat. Each of the arched springs between the facings should not be broken and all rivets should be tight.
7. Wipe the friction surface of the clutch cover (pressure plate) with mineral spirits.
8. Using a straightedge, check clutch cover (pressure plate) for flatness. The clutch cover (pressure plate) friction area should be flat within 0.020 inch and free from discoloration, burned areas, cracks, grooves, or ridges.
9. Using a surface plate, test cover for flatness. All sections around attaching bolt holes should be in contact with surface plate within 0.015 inch.
10. The cover should be a snug fit on flywheel dowels. If the clutch assembly does not meet these requirements, it should be replaced.
11. Mount clutch assembly on flywheel, being careful to properly align dowels and the alignment marks made before removal. If new clutch or flywheel is installed, align cover balance spot as close as possible to flywheel balance orange spot. Apply pressure to the alignment tool. Lightly tighten the clutch cover bolts enough to hold the disc in position.
12. To avoid distortion of the clutch cover (pressure plate), tighten bolts a few turns at a time. Use a crisscross pattern until bolts are all seated. Then tighten bolts to 30 Nm (270 inch lbs.). Remove clutch disc alignment tool,
13. Install bell housing to engine.
14. Install transmission into vehicle.