Clutch Disc: Service and Repair
REMOVAL
- Remove release bearing by pulling bearing retainers outward.
- Align spring pin with cavity of clutch housing and tap out spring pin.
INSPECTION
Check the following items, and replace if necessary.
- Release bearing, to see that it rolls freely and is free from noise, cracks, pitting or wear.
- Release sleeve and withdrawal lever rubbing surface, for wear, rust or damage.
LUBRICATION
- Apply recommended grease to contact surface and rubbing surface.
Note: Too much lubricant might damage clutch disc facing.
Clutch Disc
INSPECTION
Check the following items and replace if necessary.
- Clutch disc, for burns, discoloration, oil or grease leakage.
- Clutch disc, for wear of facing.
Wear limit of facing surface to rivet head: 0.3 mm (0.012 in).
- Check clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline (at outer edge of disc): 0.9 mm (0.035 in).
Runout limit: 1.0 mm (0.039 in).
Distance of runout check point (from hub center): 2.5 mm (4.04 in).
- Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
INSTALLATION
- Apply recommended grease to contact surface of splines.
Note: Too much lubricant may damage clutch disc facing.
Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
- Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height.
- Uneven limit: 0.7 mm (0.028 in). If out of limit, adjust the height with tool.
FLYWHEEL INSPECTION
CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.
- Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.
- Check flywheel runout.
INSTALLATION
- Insert Tool into clutch disc hub when installing clutch cover and disc.
- Be careful not to allow grease to contaminate clutch facing.
- Tighten bolts in numerical order, in two steps.
First step: 10-20 Nm (1.0-2.0 kg-m, 7-14 ft lb).
Final step: 22-29 Nm (2.2-3.0 kg-m, 16-22 ft lb).