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CL


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C TRANSMISSION/TRANSAXLE

                                                                                                                                                                  A


                                                                                                                                                                  B
                                                                                                    SECTION
                                                                                                                                    CLUTCH                        CL



                                                                                                                                                                  D


                                                                                                                                                                  E
                                                                 CONTENTS
PRECAUTIONS ......................................................... 2.         CLUTCH RELEASE MECHANISM .......................... 10                  .        F
 Precautions ............................................................. 2
                                                                       .          Components .......................................................... 10
                                                                                                                                                         .
PREPARATION .......................................................... 3
                                                                       .          Removal and Installation ....................................... 10    .
 Special Service Tools .............................................. 3.          Inspection .............................................................. 11
                                                                                                                                                         .        G
 Commercial Service Tools ....................................... 3    .          Lubrication ............................................................. 11
                                                                                                                                                         .
NOISE, VIBRATION, AND HARSHNESS (NVH)                                            CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 12                               ...
TROUBLESHOOTING ............................................... 4      .          Components .......................................................... 12
                                                                                                                                                         .
                                                                                                                                                                  H
 NVH Troubleshooting Chart .................................... 4      .          Inspection and Adjustment .................................... 12      .
CLUTCH SYSTEM -- HYDRAULIC TYPE ................ 5                     .            CLUTCH DISC ................................................... 12   .
 Components ............................................................ 5
                                                                       .            CLUTCH COVER AND FLYWHEEL .................. 13                      .
 Inspection and Adjustment ...................................... 6    .            FLYWHEEL INSPECTION ................................. 13             .         I
   CLUTCH PEDAL INSPECTION AND ADJUST-                                            Installation ............................................................. 13
                                                                                                                                                         .
   MENT ................................................................... 6
                                                                       .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 15                          .
   BLEEDING PROCEDURE ................................... 6            .          Clutch Control System ........................................... 15   .         J
CLUTCH MASTER CYLINDER ................................. 8             .          Clutch Master Cylinder (with clutch damper) ......... 15               .
 Components ............................................................ 8
                                                                       .          Clutch Operating Cylinder ..................................... 15     .
 Disassembly and Assembly .................................... 8       .          Clutch Disc ............................................................ 15
                                                                                                                                                         .
                                                                                                                                                                  K
 Inspection ................................................................ 8
                                                                       .          Clutch Cover .......................................................... 15
                                                                                                                                                         .
OPERATING CYLINDER ........................................... 9       .          Clutch Pedal .......................................................... 15
                                                                                                                                                         .
 Components ............................................................ 9
                                                                       .
 Inspection ................................................................ 9
                                                                       .                                                                                           L



                                                                                                                                                                  M




                                                                            CL-1
                                          PRECAUTIONS

PRECAUTIONS                                                         PFP:00001

Precautions                                                             ECS006HE


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, operating cylinder and clutch damper.
q   Never use mineral oils such as gasoline or kerosene. It will
    ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do    SBR686C

not use compressed air.




                                                 CL-2
                                                       PREPARATION

PREPARATION                                                                                                                    PFP:00002
                                                                                                                                              A
Special Service Tools                                                                                                              ECS006HF

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number
                                                                                                                                              B
  (Kent-Moore No.)                                                                       Description
  Tool name
  ST20630000                                                                             Installing clutch cover and clutch disc
  (J26366)                                                                               a: 15.9 mm (0.626 in) dia.                           CL
   Clutch aligning bar                                                                   b: 22.8 mm (0.898 in) dia.
                                                                                         c: 55 mm (2.17 in)

                                                                                                                                              D

                                                                         NT405


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


                                                                         NT404
                                                                                                                                              G
Commercial Service Tools                                                                                                           ECS006HG


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



                                                                         NT360
                                                                                                                                               J
  Bearing puller                                                                         Removing release bearing

                                                                                                                                              K


                                                                                                                                               L
                                                                         NT077


  Bearing drift                                                                          Installing release bearing
                                                                                         a: 52 mm (2.05 in) dia.                              M
                                                                                         b: 45 mm (1.77 in) dia.




                                                                         NT474




                                                                CL-3
                                             Symptom
                                                                                                                                   (Possible cause)
                                                                                                                                   SUSPECTED PARTS




       engage
                              Clutch slips
                                                                                                                                                                      Reference page




                                                 Clutch noisy


       Clutch does not dis-
                                                                Clutch pedal spongy
                                                                                      Clutch grabs/chatters
                                                                                                              CLUTCH PEDAL (Inspection and Adjustment)               CL-6




            1
                              1
                                                                                                              CLUTCH LINE (Air in line)                              CL-6




            2
                                                                1
                                                                                                                                                                                                                                                                                                          NVH Troubleshooting Chart




                                                                                                              MASTER CYLINDER PISTON CUP (Damaged)                   CL-8




            3
                                                                2
                                                                                                              OPERATING CYLINDER PISTON CUP (Damaged)                CL-9




            4
                                                                2
                                                                                                                                                         EM-44 (KA24DE), EM-124 (VG33E
                                                                                                              ENGINE MOUNTING (Loose)




                                                                                      1
                                                                                                                                                                   & VG33ER)




CL-4
                                                                                                              RELEASE BEARING (Worn, dirty or damaged)               CL-11




                                                 1
                                                                                                              CLUTCH DISC (Out of true)




            5
                                                                                                              CLUTCH DISC (Runout is excessive)




            5
                                                                                      2
                                                                                                              CLUTCH DISC (Lining broken)




            5
                                                                                                              CLUTCH DISC (Dirty or burned)




            5
                                                                                                                                                                     CL-12
                                                                                                              CLUTCH DISC (Oily)




            5
                              2
                                                                                      2
                                                                                                              CLUTCH DISC (Worn out)




                              2
                                                                                      2
                                                                                                              CLUTCH DISC (Hardened)
                                                                                      2
                                                                                                                                                                                         cause of the problem. Check each part in order. If necessary, repair or replace these parts.
                                                                                                                                                                                                                                                                                                          NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING




                                                                                                              CLUTCH DISC (Lack of spline grease)




            5
                                                                                                              DIAPHRAGM SPRING (Damaged)




            6
                              3
                                                                                                                                                                     CL-13
                                                                                                              DIAPHRAGM SPRING (Out of tip alignment)


            6
                                                                                      2
                                                                                                                                                                                                                                                                                                                                                                  NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING




                                                                                                              PRESSURE PLATE (Distortion)                            CL-13
            7
                              4


                                                                                                              FLYWHEEL (Distortion)                                  CL-13
                              5
                                                                                                                                                                                                                                                                                                                                            PFP:00003



                                                                                                                                                                                         Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely
                                                                                                                                                                                                                                                                                                            ECS006HH
                              CLUTCH SYSTEM -- HYDRAULIC TYPE

CLUTCH SYSTEM -- HYDRAULIC TYPE                                                                               PFP:30502
                                                                                                                                 A
Components                                                                                                            ECS006HI




                                                                                                                                 B


                                                                                                                                 CL



                                                                                                                                 D


                                                                                                                                 E



                                                                                                                                 F


                                                                                                                                 G


                                                                                                                                 H



                                                                                                                                  I


                                                                                                                                  J



                                                                                                                                 K


                                                                                                                                  L



                                                                                                                                 M




                                                                                                             WCL044

 1.   Clutch pedal bracket               2.   Clutch interlock switch          3.   Clutch master cylinder
 4.   Fulcrum pin                        5.   Bushing                          6.   Clevis pin
 7.   Clutch pedal                       8.   Lock nut                         9.   ASCD clutch switch
 10. Pedal stopper bolt (without ASCD)   11. Snap pin                          12. Assist spring
 13. Clutch disc                         14. Clutch cover                      15. Release bearing
 16. Release bearing sleeve              17. Withdrawal lever                  18. Operating cylinder
 19. Air bleeder                         20. Clutch damper (not serviceable)   21. Flare nut
 22. Bushing




                                                         CL-5
                             CLUTCH SYSTEM -- HYDRAULIC TYPE

Inspection and Adjustment                                                                          ECS006HJ

CLUTCH PEDAL INSPECTION AND ADJUSTMENT
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.
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
     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
     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-
     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.
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
     pedal and re-verify that the clevis pin floats freely in the bore of
     the pedal.
                                                                                                WCIA0146E



3.   Adjust the clearance "C" while fully depressing the clutch pedal
     (with the clutch interlock switch) as shown.
        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,
     clutch release bearing, etc.) for sticking or binding.
a.   If any sticking or binding is noted, repair or replace the related
     parts as necessary.
b.   If the hydraulic system was necessary, bleed the clutch hydrau-
     lic system. Refer to CL-6, "BLEEDING PROCEDURE" .
     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.




                                                                                                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.
1. Top off the clutch master cylinder reservoir with the recommended brake fluid "DOT 3".




                                                       CL-6
                            CLUTCH SYSTEM -- HYDRAULIC TYPE

     CAUTION:
     Do not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed A
     on painted areas, wash it away with water immediately.
2.   Connect a transparent vinyl tube to the air bleeder as shown.
3.   Slowly depress the clutch pedal to its full stroke and release it                                     B
     completely. Repeat this operation several times at 2 to 3 sec-
     onds intervals.
4.   Open the air bleeder with the clutch pedal fully depressed.                                          CL
5.   Close the air bleeder and tighten to specification.
        Air bleeder             : 5.9 - 9.8 N



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