Clutch: Service and Repair
CLUTCH UNIT REMOVAL/INSTALLATION [G66M-R]
1. Disconnect the negative battery cable.
2. Remove the aerodynamic under cover and the splash shield as a single unit. Service and Repair Service and Repair
3. Drain the manual transaxle oil. Manual Transaxle Oil Replacement
4. Disconnect and/or remove the following parts in the engine compartment.
a. Remove the air cleaner component. (ex: air cleaner, air hose) Service and Repair
b. Remove the battery component. (ex: battery, battery tray) Removal and Replacement
c. Disconnect the clutch pipe and hose No.2 from MTX. Service and Repair
d. Disconnect the control cable from MTX. Service and Repair
e. Disconnect the connectors and GND wiring harness from the MTX.
f. Remove the brackets from MTX.
5. Disconnect and/or remove the following parts related to the suspension and axle.
a. Remove the front tires. Procedures
b. Disconnect the clip securing the brake hose from the shock absorber. Brake Hose (Front) Removal/Installation
c. Disconnect the ABS wheel-speed sensors from the steering knuckles. Front
d. Disconnect the tie-rod end ball joints from the steering knuckles. Service and Repair
e. Disconnect the stabilizer control links (upper side) from the shock absorbers. Front Suspension - Stabilizer Removal/Installation
f. Disconnect the front lower arms from the steering knuckles. Service and Repair
g. Disconnect the drive shaft (LH) from the MTX. Drive Shaft Removal/Installation
h. Disconnect the drive shaft (RH) from the joint shaft. Drive Shaft Removal/Installation
i. Remove the joint shaft. Drive Shaft Removal/Installation
6. Disconnect/remove the parts from underside of vehicle
a. Remove the hanger as shown in the figure.
b. Disconnect the clutch release cylinder from the MTX. Service and Repair
c. Remove the starter. Removal and Replacement
7. Install the SST using the following procedure.
CAUTION:
- Refer to the SST instruction manual for the basic handing procedure.
a. Remove the windshield wiper arm and blade. Windshield Wiper Arm And Blade Removal/Installation
b. Remove the front fender molding. Cowl Grille Removal/Installation
c. Remove the cowl grille. Cowl Grille Removal/Installation
d. Remove the cowl panel. Cowl Panel Removal/Installation
e. Protect the windshield using tape.
f. Disconnect the No.1 brake fluid reserve tank from brake fluid reserve tank bracket. Service and Repair
g. Align the bolt of the shock absorber (RH) shown in the figure with the rear shaft hole for the right side of the SST.
h. Align the bolt of the shock absorber (LH) shown in the figure with the rear shaft hole for the left side of the SST.
i. Install one front foot No.2 to each of the left and right front shafts of the SST, and then align the holes of the SST front shafts with the bolt on the left and right side of each front side frame.
j. Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.
k. Make sure each joint is securely tightened.
8. Remove the MTX. Manual Transaxle Removal/Installation
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Add the specified amount of specified transaxle oil. Manual Transaxle Oil Replacement
Clutch Cover and Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Pilot Bearing Removal Note
NOTE:
- The pilot bearing does not need to be removed unless you are replacing it.
1. Remove the pilot bearing using the SST.
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the lock bolts in the order shown in the figure and remove the flywheel.
3. Inspect for oil leakage from the crankshaft rear oil seal.
- If there is any malfunction, replace the crankshaft rear oil seal. Service and Repair
Flywheel Installation Note
1. Clean the crankshaft thread holes.
2. Install the flywheel to the crankshaft.
3. Temporarily tighten the new lock bolts.
4. Hold the flywheel using the SST.
5. Tighten the lock bolts completely in the order shown in the figure and install the flywheel.
Tightening torque
- 108-116 Nm {11.1-11.8 kgf-m, 80-85 ft-lbf}
Pilot Bearing Installation Note
1. Install new pilot bearing to the specified position using the following tools.
Tool
- Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20-22 mm)
- Use the adapter with the 20 mm side of the A160M7 (20-22 mm) facing the pilot bearing side.
Substitution tool
- Outer diameter: 21 mm {0.83 in}
- Inner diameter: 19 mm {0.75 in}
Standard position
- Distance A of pilot bearing from crankshaft end: 4.0-5.0 mm {0.16-0.19 in}
Clutch Disc and Cover Installation Note
1. Hold the clutch disc position using the SST.
2. Hold the clutch unit using the SST.
3. Tighten the bolts in Min. 2 stages.
a. Temporarily tighten the bolts in the order shown in the figure.
b. Tighten the bolts completely in the order shown in the figure and install the clutch disc and cover.
Tightening torque
- 25-33 Nm {2.6-3.3 kgf-m, 19-24 ft-lbf}