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CLUTCH
C TRANSMISSION/TRANSAXLE
A
B
SECTION
CLUTCH CL
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . OPERATING CYLINDER ......................................... 12 . F
Caution .................................................................... 2
. Removal and Installation ....................................... 12 .
PREPARATION .......................................................... 3. REMOVAL .......................................................... 12
.
Special Service Tools .............................................. 3 . INSTALLATION .................................................. 12 . G
Commercial Service Tool ........................................ 3 . Disassembly and Assembly ................................... 12 .
NOISE, VIBRATION, AND HARSHNESS (NVH) DISASSEMBLY .................................................. 12 .
TROUBLESHOOTING ............................................... 4 . INSPECTION AFTER DISASSEMBLY ............... 12 .
H
NVH Troubleshooting Chart .................................... 4 . ASSEMBLY ........................................................ 12
.
CLUTCH ............................................................... 4
. CLUTCH PIPING ...................................................... 13
.
CLUTCH PEDAL ....................................................... 5 . Removal and Installation ....................................... 13 .
On-Vehicle Inspection and Adjustment ................... 5 . CLUTCH RELEASE MECHANISM .......................... 14 . I
HEIGHT ADJUSTMENT ...................................... 5 . Removal and Installation ....................................... 14 .
CLUTCH INTER LOCK SWITCH POSITION REMOVAL .......................................................... 14
.
ADJUSTMENT ..................................................... 5 . INSPECTION AFTER REMOVAL ...................... 14 . J
FREE PLAY INSPECTION ................................... 6 . INSTALLATION .................................................. 15 .
CLEARANCE CHECK .......................................... 6 . CLUTCH DISC, CLUTCH COVER ........................... 16 .
Removal and Installation ......................................... 6 . Removal and Installation ....................................... 16 .
K
REMOVAL ............................................................ 7
. REMOVAL .......................................................... 16
.
INSPECTION AFTER REMOVAL ........................ 7 . INSPECTION AND ADJUSTMENT AFTER
INSTALLATION .................................................... 7 . REMOVAL .......................................................... 16
.
CLUTCH FLUID ......................................................... 8. INSTALLATION .................................................. 17 . L
Bleeding .................................................................. 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 18 .
CLUTCH MASTER CYLINDER ................................. 9 . Clutch Control System ........................................... 18 .
Removal and Installation ......................................... 9 . Clutch Master Cylinder .......................................... 18 . M
REMOVAL ............................................................ 9
. Clutch Operating Cylinder ..................................... 18 .
INSTALLATION .................................................. 10 . Clutch Disc ............................................................ 18
.
Disassembly and Assembly .................................. 10 . Clutch Cover .......................................................... 18
.
DISASSEMBLY .................................................. 10 . Clutch Pedal .......................................................... 18
.
INSPECTION AFTER DISASSEMBLY ...............11 .
ASSEMBLY .........................................................11 .
CL-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ACS0014T
q Recommended fluid is brake fluid "DOT 3".
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas.
q When removing and installing clutch piping, use Tool.
q Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
q Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
SBR686C
CL-2
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ACS0014U
The actual shapes of Kent-Moore tool may differ from those of special service tools illustrated here.
Tool name B
(Kent-Moore No.) Description
Tool number
CL
Drift
KV30101400
( -- ) Installing clutch release bearing
D
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.
ZZA0838D
E
Diaphragm adjusting wrench
Adjusting unevenness of diaphragm spring of F
ST20050240
clutch cover
( -- )
ZZA0508D G
Clutch aligning bar
ST20670000 H
( -- ) Installing clutch disc
a: 15 mm (0.59 in) dia.
b: 23 mm (0.91 in) dia.
I
ZZA1178D
Commercial Service Tool ACS0014V
J
Tool name Description
K
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin
L
ZZA0515D
M
Power tool Loosening bolts and nuts
PBIC0190E
1. Flare nut crowfoot
2. Torque wrench Removing and installing clutch piping
a: 10 mm (0.39 in)
S-NT360
CL-3
Symptom
CLUTCH
Reference page
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
Clutch does not disengage
NVH Troubleshooting Chart
CLUTCH PEDAL (Free play out of adjustment) CL-5
1
1
CLUTCH LINE (Air in line) CL-8
2
1
tion. If necessary, repair or replace these parts.
MASTER CYLINDER PISTON CUP (Damaged) CL-10
3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-12
4
2
ENGINE MOUNTING (Loose) EM-89
1
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-14
1
CLUTCH DISC (Out of true) CL-16
5
CLUTCH DISC (Runout is excessive) CL-16
5
2
CLUTCH DISC (Lining broken) CL-16
5
CLUTCH DISC (Dirty or burned) CL-16
5
CLUTCH DISC (Oily) CL-16
5
2
2
2 CLUTCH DISC (Worn out) CL-16
2
CLUTCH DISC (Hardened) CL-16
2
CLUTCH DISC (Lack of spline grease) CL-16
5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
DIAPHRAGM SPRING (Damaged) CL-16
6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-16
6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion) CL-16
7
4
FLYWHEEL (Distortion) EM-118
5
PFP:00003
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ACS0014W
CLUTCH PEDAL
CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ACS0014X
HEIGHT ADJUSTMENT
1. Check that clutch pedal height H1 from the melt sheet is within
B
the specified range.
Pedal height H1 : 171 - 179 mm (6.73 - 7.05 in)
2. If pedal height H1 is outside the specification, loosen ASCD CL
cancel switch lock nut B and turn ASCD cancel switch. next
loosen clevis lock nut A and turn push rod to adjust.
3. When pedal height comes into the specified range, tighten D
ASCD cancel switch lock nut B and clevis lock nut A to the spec-
ified torque.
Lock nut A: E
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