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C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
QG18DE Inspection and Adjustment .................................... 17 . F
CLUTCH DISC ................................................... 17 .
PRECAUTIONS ......................................................... 3 . CLUTCH COVER AND FLYWHEEL .................. 18 .
Precautions ............................................................. 3
. FLYWHEEL INSPECTION ................................. 18 . G
PREPARATION .......................................................... 4 . Installation ............................................................. 18
.
Special Service Tools .............................................. 4 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 19 .
Commercial Service Tools ....................................... 4 . Clutch Control System ........................................... 19 .
NOISE, VIBRATION, AND HARSHNESS (NVH) H
Clutch Master Cylinder .......................................... 19 .
TROUBLESHOOTING ............................................... 5 . Clutch Operating Cylinder ..................................... 19 .
NVH Troubleshooting Chart .................................... 5 . Clutch Disc ............................................................ 19
.
CLUTCH SYSTEM ..................................................... 6 . Clutch Cover .......................................................... 19
. I
Components ............................................................ 6
. Clutch Pedal .......................................................... 19
.
Inspection and Adjustment ...................................... 7 .
CLUTCH PEDAL INSPECTION AND ADJUST- J
MENT ................................................................... 7
.
QR25DE
BLEEDING PROCEDURE ................................... 7 . PRECAUTIONS ....................................................... 20 .
CLUTCH MASTER CYLINDER ................................. 9 . Precautions ............................................................ 20
.
Components ............................................................ 9
. K
PREPARATION ........................................................ 21 .
Removal .................................................................. 9
. Special Service Tools ............................................ 21 .
Disassembly ............................................................ 9
. Commercial Service Tools ..................................... 21 .
Inspection .............................................................. 10
. NOISE, VIBRATION, AND HARSHNESS (NVH) L
Assembly ............................................................... 10
. TROUBLESHOOTING ............................................. 22 .
Installation ............................................................. 10
. NVH Troubleshooting Chart .................................. 22 .
OPERATING CYLINDER ..........................................11 . CLUTCH SYSTEM ................................................... 23 . M
Components ...........................................................11
. Components .......................................................... 23
.
Removal .................................................................11
. Inspection and Adjustment .................................... 24 .
Disassembly ...........................................................11
. CLUTCH PEDAL INSPECTION AND ADJUST-
Inspection ...............................................................11
. MENT ................................................................. 24
.
Assembly ............................................................... 12
. BLEEDING PROCEDURE ................................. 24 .
Installation ............................................................. 12
. CLUTCH MASTER CYLINDER ............................... 26 .
PIPING ..................................................................... 13
. Components .......................................................... 26
.
Removal ................................................................ 13
. Removal ................................................................ 26
.
Installation ............................................................. 13
. Disassembly .......................................................... 26
.
CLUTCH RELEASE MECHANISM ......................... 14 . Inspection .............................................................. 26
.
Components .......................................................... 14
. Assembly ............................................................... 27
.
Removal ................................................................ 14
. Installation ............................................................. 27
.
Inspection .............................................................. 14
. OPERATING CYLINDER ......................................... 28 .
Installation ............................................................. 14
. Components .......................................................... 28
.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 17 ... Removal ................................................................ 28
.
Components .......................................................... 17
. Disassembly .......................................................... 28
.
Removal ................................................................ 17
.

CL-1
Inspection .............................................................. 28
. Removal .................................................................33
.
Assembly ............................................................... 29
. Inspection and Adjustment .....................................33 .
Installation .............................................................. 29
. CLUTCH DISC ....................................................33 .
PIPING ...................................................................... 30
. CLUTCH COVER AND FLYWHEEL ...................34 .
Removal ................................................................ 30
. FLYWHEEL INSPECTION ..................................34 .
Installation .............................................................. 30
. Installation ..............................................................34
.
CLUTCH RELEASE MECHANISM .......................... 31 . SERVICE DATA AND SPECIFICATIONS (SDS) .....35 .
Components .......................................................... 31. Clutch Control System ...........................................35 .
Removal ................................................................ 31
. Clutch Master Cylinder ...........................................35 .
Inspection After Removal ...................................... 31 . Clutch Operating Cylinder ......................................35 .
Installation .............................................................. 32
. Clutch Disc .............................................................35
.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 33 ... Clutch Cover ..........................................................35
.
Components .......................................................... 33. Clutch Pedal ...........................................................35
.

CL-2
PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Precautions ECS005RJ

q The recommended clutch system hydraulic fluid is brake fluid "DOT 3".
q Do not reuse drained brake fluid. B
q Be careful not to splash brake fluid on painted areas; it may cause paint damage. If any brake fluid
is splashed on painted areas, wash it away with water immediately.
q Use a flare nut wrench (commercial service tool) when CL
removing or installing the clutch hydraulic tubes.
q Use new brake fluid to clean or wash any parts of the clutch
master cylinder and operating cylinder. D
q Never use any type of mineral oil such as gasoline or kero-
sene to clean or wash any parts of the clutch system. It will
ruin the rubber parts of the hydraulic system. E

SBR686C
F

WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air. G

CL-3
PREPARATION
[QG18DE]
PREPARATION PFP:00002

Special Service Tools ECS005RK

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
KV30101600 (New) Installing clutch cover and clutch disc
KV30101000 (Former) a: 15.9 mm (0.626 in) dia.
(J33213) b: 17.9 mm (0.705 in) dia.
Clutch aligning bar c: 40 mm (1.57 in)

NT641

ST20050240 Adjusting unevenness of diaphragm spring of
( -- ) clutch cover
Diaphragm spring adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

S-NT404

KV32101000 Removing and installing spring pin
(J25689-A) a: 4 mm (0.16 in) dia.
Pin punch

S-NT410

Commercial Service Tools ECS005RL

Tool name Description
1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)

S-NT360

CL-4
Symptom
Reference page

Clutch slips
Clutch noisy
Suspected parts (Possible cause)

Clutch pedal spongy
Clutch grabs/chatters

Clutch does not disengage
NVH Troubleshooting Chart

Clutch pedal (Inspection and adjustment) CL-7

1
1
Clutch line (Air in line) CL-7

2
1
Master cylinder piston cup (Damaged) CL-9

3
2
Operating cylinder piston cup (Damaged) CL-11

4
2
Engine mounting (Loose) EM-62, "Removal and Installation"

CL-5
Release bearing (Worn, dirty or damaged) CL-14

1
Clutch disc (Out of true)

5
Check each part in order. If necessary, repair or replace these parts.

Clutch disc (Runout is excessive)

5
2
Clutch disc (Lining broken)

5
Clutch disc (Dirty or burned) CL-17

5
Clutch disc (Oily)

5
2
2
Clutch disc (Worn out)

2
2

Clutch disc (Hardened)
2

Clutch disc (Lack of spline grease) CL-17
5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

6 Diaphragm spring (Damaged)
3

Diaphragm spring (Out of tip alignment) CL-18
6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

Clutch cover (Distortion)
7
4

Flywheel (Distortion) CL-18
5
[QG18DE]
PFP:00003

ECS005RM

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.

L
F

K
E
B
A

H
D

M
CLUTCH SYSTEM
[QG18DE]
CLUTCH SYSTEM PFP:30502

Components ECS005RN

WCL005

1. Clutch pedal bracket 2. ASCD clutch switch (if equipped) 3. Clutch interlock switch
4. Clutch pedal 5. Clutch master cylinder 6. Nipple
7. Clutch damper (not serviceable) 8. Clevis 9. Hose clamp
10. Reservoir hose 11. Reservoir tank 12. Reservoir cap
13. Clutch disc 14. Clutch cover 15. Withdrawal lever
16. Clutch lever 17. Spring pin 18. Release bearing
19. Operating cylinder 20. Clutch hose 21. Spacer
22. Release bearing spring 23. Clutch tube

CL-6
CLUTCH SYSTEM
[QG18DE]
Inspection and Adjustment ECS005RO

CLUTCH PEDAL INSPECTION AND ADJUSTMENT A
1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal. B
a. If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper CL
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of D
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the pin is still not free, remove the pin and check for deforma-
E
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
F
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the G
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
WCIA0146E
H
3. Adjust the clearance "C" while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
I
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever, J
clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related
parts as necessary. K
b. If any hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "BLEEDING PROCEDURE" .
NOTE: L
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all of the air from the system.
M

SCL800

BLEEDING PROCEDURE
CAUTION:
Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.

CL-7
CLUTCH SYSTEM
[QG18DE]
1. Top off the clutch master cylinder reservoir with the recom-
mended brake fluid "DOT 3". Then attach the additional supply
tank as shown.
CAUTION:
Do not to splash brake fluid on painted areas; it may cause
paint damage. If brake fluid is splashed on painted areas,
wash it away with water immediately.
2. Connect a transparent vinyl tube to the air bleeder valve as
shown.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
4. Open the air bleeder valve with the clutch pedal fully depressed.

WCL008

5. Close the air bleeder valve and tighten to specification.
Air bleeder valve : 5.9 - 9.8 N

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