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C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

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

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)

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

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

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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