Clutch: Service and Repair

CLUTCH UNIT (R155/R155F)





COMPONENTS

OVERHAUL
1. REMOVE MANUAL TRANSMISSION UNIT ASSY (R155 TRANSMISSION)
2. REMOVE MANUAL TRANSMISSION UNIT ASSY (R155F TRANSMISSION)





3. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork together with the clutch release bearing from the transmission assy.
4. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing assy from the clutch release fork.
5. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the transaxle assy.
6. REMOVE RELEASE BEARING HUB CLIP
7. REMOVE CLUTCH RELEASE FORK BOOT





8. REMOVE CLUTCH COVER ASSY
a. Align the matchmark on the clutch cover assy with the one on the flywheel sub-assembly.
b. Loosen each set bolt one turn at a time until the spring tension is released.
c. Remove the 6 bolts and clutch cover assy.

NOTICE: Do not drop the clutch disc assy.

9. REMOVE CLUTCH DISC ASSY

NOTICE: Keep the lining part of the clutch disc assy, pressure plate and surface of the flywheel sub-assy free from oil and foreign matter.





10. INSPECT CLUTCH DISC ASSY
a. Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc assy.
b. Install the clutch disc assy onto the transaxle assy.

NOTICE: Take care not to insert the clutch disc assy in the wrong orientation.





c. Using a dial indicator, check the clutch disc assy runout.
Minimum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc assy.





11. INSPECT CLUTCH COVER ASSY
a. Using vernier calipers, inspect the depth and width of wear of the diaphragm spring.
Minimum:
A (Depth): 0.5 mm (0.020 inch)
B (Width): 6.0 mm (0.236 inch)
If necessary, replace the clutch cover assy.





12. INSPECT FLYWHEEL SUB-ASSY
a. Using a dial indicator, inspect the flywheel sub-assembly runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assembly.





13. INSPECT INPUT SHAFT BEARING
a. Turn the bearing by hand while applying force in the rotation direction.
If the bearing is stuck or difficult to turn, replace the input shaft bearing.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.





14. REMOVE INPUT SHAFT BEARING
a. Remove the 4 bolts at diametrically opposite points.
b. Using SST, remove the pilot bearing.
SST 09303-35011





15. INSTALL INPUT SHAFT BEARING
a. Using SST and a hammer, install the input shaft bearing.
SST 09304-30012

HINT: After assembling the input shaft bearing to the hub, make sure that it rotates smoothly.

b. Install 4 new bolts.
Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.)





c. Mark each bolt with paint as shown in the illustration.
d. Retighten each bolt by 90°.
e. Check that the mark on each bolt is at a 90° angle from its original position.





16. INSPECT CLUTCH RELEASE BEARING ASSY
a. Turn the release bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.

If necessary, replace the release bearing assy.





17. INSTALL CLUTCH DISC ASSY
a. Insert SST into the clutch disc assy, then insert them into the flywheel sub-assembly.
SST 09301-00210

NOTICE: Take care not to insert clutch disc assy in the wrong orientation.





18. INSTALL CLUTCH COVER ASSY
a. Align the matchmarks on the clutch cover assy and flywheel sub-assy.
b. Tighten the 6 bolts, in the order shown in the illustration, starting with the bolt located near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

HINT:
^ Following the order in the illustration, uniformly tighten the bolts.
^ Move SST up and down, right and left gently after checking that the disc is in the center, and tighten the bolts.





19. INSPECT AND ADJUST CLUTCH COVER ASSY
a. Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If the alignment is not as specified, adjust the diaphragm spring tip alignment using SST.
SST 09333-00013
20. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support onto the transaxle assy.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
21. INSTALL RELEASE BEARING HUB CLIP





22. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Apply release hub grease to the release fork and release bearing assy contact surfaces, release fork and push rod contact surface and release fork pivot point.
Sealant: Part No.08887-01806, RELEASE HUB GREASE or equivalent
b. Install the release fork onto the release bearing assy.
23. INSTALL CLUTCH RELEASE BEARING ASSY
a. Apply clutch spline grease to the input shaft spline.
Sealant: Part No.08887-01706, CLUTCH SPLINE GREASE or equivalent
b. Install the bearing onto the release fork, and then install them onto the transaxle assy.

NOTICE: After installation, move the fork forward and backward to check that the release bearing slides smoothly.

24. INSTALL CLUTCH RELEASE FORK BOOT
25. INSTALL MANUAL TRANSMISSION UNIT ASSY (R155 TRANSMISSION)
26. INSTALL MANUAL TRANSMISSION UNIT ASSY (R155F TRANSMISSION)