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C TRANSMISSION/TRANSAXLE
A
B
SECTION
CLUTCH CL
D
E
CONTENTS
QG18DE CLUTCH DISC ................................................... 17 . F
CLUTCH COVER ............................................... 18 .
PRECAUTIONS ......................................................... 3 . FLYWHEEL ........................................................ 18 .
Precautions ............................................................. 3
. Installation ............................................................. 18
. G
PREPARATION .......................................................... 4 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 19 .
Special Service Tools .............................................. 4 . Clutch Control System ........................................... 19 .
Commercial Service Tools ....................................... 4 . Clutch Master Cylinder .......................................... 19 .
NOISE, VIBRATION, AND HARSHNESS (NVH) H
Clutch Operating Cylinder ..................................... 19 .
TROUBLESHOOTING ............................................... 5 . Clutch Disc ............................................................ 19
.
NVH Troubleshooting Chart .................................... 5 . Clutch Cover .......................................................... 19
.
CLUTCH SYSTEM ..................................................... 6 . Clutch Pedal .......................................................... 19
. I
Components ............................................................ 6
.
Inspection and Adjustment ...................................... 7 .
ADJUSTING CLUTCH PEDAL ............................ 7 .
QR25DE
J
BLEEDING PROCEDURE ................................... 7 . PRECAUTIONS ....................................................... 20 .
CLUTCH MASTER CYLINDER ................................. 9 . Precautions ............................................................ 20
.
Components ............................................................ 9
. PREPARATION ........................................................ 21 .
Removal .................................................................. 9
. K
Special Service Tools ............................................ 21 .
Installation ............................................................... 9
. Commercial Service Tools ..................................... 21 .
Disassembly .......................................................... 10
. NOISE, VIBRATION, AND HARSHNESS (NVH)
Inspection .............................................................. 10
. TROUBLESHOOTING ............................................. 22 . L
Assembly ............................................................... 10
. NVH Troubleshooting Chart .................................. 22 .
OPERATING CYLINDER ..........................................11 . CLUTCH SYSTEM ................................................... 23 .
Components ...........................................................11
. Components .......................................................... 23
. M
Removal .................................................................11
. Inspection and Adjustment .................................... 24 .
Disassembly ...........................................................11
. ADJUSTING CLUTCH PEDAL ........................... 24 .
Inspection ...............................................................11
. BLEEDING PROCEDURE ................................. 24 .
Assembly ................................................................11
. CLUTCH MASTER CYLINDER ............................... 26 .
Installation ............................................................. 12
. Components .......................................................... 26
.
PIPING ..................................................................... 13
. Removal ................................................................ 26
.
Removal ................................................................ 13
. Installation ............................................................. 26
.
Installation ............................................................. 13
. Disassembly .......................................................... 27
.
CLUTCH RELEASE MECHANISM ......................... 14 . Inspection .............................................................. 27
.
Components .......................................................... 14
. Assembly ............................................................... 27
.
Removal ................................................................ 14
. OPERATING CYLINDER ......................................... 28 .
Inspection .............................................................. 14
. Components .......................................................... 28
.
Installation ............................................................. 14
. Removal ................................................................ 28
.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 17 ... Disassembly .......................................................... 28
.
Components .......................................................... 17
. Inspection .............................................................. 28
.
Removal ................................................................ 17
.
Inspection and Adjustment .................................... 17 .
CL-1
Assembly ............................................................... 28
. Inspection and Adjustment .....................................33 .
Installation .............................................................. 29
. CLUTCH DISC ....................................................33 .
PIPING ...................................................................... 30
. CLUTCH COVER ................................................34 .
Removal ................................................................ 30
. FLYWHEEL .........................................................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 .............................................................. 31
. Clutch Disc .............................................................35
.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 33 ... Clutch Cover ..........................................................35
.
Components .......................................................... 33. Clutch Pedal ...........................................................35
.
Removal ................................................................ 33
.
CL-2
PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Precautions ECS00489
q Recommended 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 brake fluid is splashed on painted
areas, wash it away with water immediately. CL
q Use flare nut wrench when removing or installing clutch
hydraulic tubes.
q Use new brake fluid to clean or wash all parts of master cyl- D
inder and operating cylinder.
q Never use mineral oils such as gasoline or kerosene. It will SBR686C
ruin the rubber parts of the hydraulic system. E
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
F
G
H
I
J
K
L
M
CL-3
PREPARATION
[QG18DE]
PREPARATION PFP:00002
Special Service Tools ECS0048A
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
KV30101600 (New) Installing clutch cover and clutch disc
KV30101000 (Former) a: 15.9 mm (0.626 in) dia.
(J-33213) 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
(J-25689-A) a: 4 mm (0.16 in) dia.
Pin punch
S-NT410
Commercial Service Tools ECS0048B
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
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
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-54, "Removal and Installation"
1
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
DIAPHRAGM SPRING (Damaged)
6
3 DIAPHRAGM SPRING (Out of tip alignment) CL-18
6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
7 CLUTCH COVER (Distortion)
4
FLYWHEEL (Distortion) CL-18
5
[QG18DE]
PFP:00003
ECS0048C
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
I
J
L
F
K
E
B
A
CL
H
D
G
M
CLUTCH SYSTEM
[QG18DE]
CLUTCH SYSTEM PFP:30502
Components ECS0048D
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 ECS0048E
ADJUSTING CLUTCH PEDAL 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 fluid level at master cylinder during 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 the air from the system.
1. Top off reservoir with recommended brake fluid.
CL-7
CLUTCH SYSTEM
[QG18DE]
CAUTION:
Be careful 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 air bleeder valve to drain the
fluid into a clean container.
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.
WCIA0018E
5. Close the air bleeder valve.
Air bleeder valve tightening torque : 5.9 - 9.8 N◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo