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CLUTCH
C TRANSMISSION/TRANSAXLE
A
SECTION CL CLUTCH
B
CL
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . REMOVAL .......................................................... 11
. F
Caution .................................................................... 2
. INSTALLATION .................................................. 11 .
PREPARATION .......................................................... 3. Disassembly and Assembly ................................... 11 .
Special Service Tools .............................................. 3 . DISASSEMBLY .................................................. 11 . G
Commercial Service Tools ....................................... 3 . INSPECTION AFTER DISASSEMBLY ............... 11 .
NOISE, VIBRATION AND HARSHNESS (NVH) ASSEMBLY ........................................................ 11
.
TROUBLESHOOTING ............................................... 4 . CLUTCH PIPING ...................................................... 12
.
H
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 12 .
CLUTCH ............................................................... 4
. CLUTCH RELEASE MECHANISM .......................... 13 .
CLUTCH PEDAL ....................................................... 5 . Removal and Installation ....................................... 13 .
On-Vehicle Inspection and Adjustment ................... 5 . REMOVAL .......................................................... 13
. I
Removal and Installation ......................................... 6 . INSPECTION AFTER REMOVAL ...................... 13 .
REMOVAL ............................................................ 6
. INSTALLATION .................................................. 14 .
INSPECTION AFTER REMOVAL ........................ 6 . CLUTCH DISC, CLUTCH COVER ........................... 15 . J
INSTALLATION .................................................... 6 . Removal and Installation ....................................... 15 .
CLUTCH FLUID ......................................................... 7. REMOVAL .......................................................... 15
.
Bleeding .................................................................. 7
. INSPECTION AND ADJUSTMENT AFTER
K
CLUTCH MASTER CYLINDER ................................. 8 . REMOVAL .......................................................... 15
.
Removal and Installation ......................................... 8 . INSTALLATION .................................................. 16 .
REMOVAL ............................................................ 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 17 .
INSTALLATION .................................................... 9 . Clutch Control System ........................................... 17 . L
Disassembly and Assembly .................................... 9 . Clutch Master Cylinder .......................................... 17 .
DISASSEMBLY .................................................... 9 . Clutch Operating Cylinder ..................................... 17 .
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Disc ............................................................ 17
. M
ASSEMBLY ........................................................ 10 . Clutch Cover .......................................................... 17
.
OPERATING CYLINDER ..........................................11 . Clutch Pedal .......................................................... 17
.
Removal and Installation ........................................11 .
CL-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ACS004NY
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 ACS004NZ
The actual shapes of Kent-Moore tool may differ from those of special service tools illustrated here.
Tool number B
(Kent-Moore No.) Description
Tool name
KV30101400 Installing release bearing CL
( -- )
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.
Drift D
ZZA0838D
E
ST20050240 Adjusting unevenness of diaphragm spring of
( -- ) clutch cover
Diaphragm adjusting wrench
F
ZZA0508D G
ST20670000 Installing clutch disc
( -- )
a: 15 mm (0.59 in) dia. H
b: 23 mm (0.91 in) dia.
Clutch aligning bar
I
ZZA1178D
Commercial Service Tools ACS004O0
J
Tool name Description
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin K
L
ZZA0515D
Power tool Loosening bolts and nuts M
PBIC0190E
1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench
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 (Inspection and adjustment) .CL-5, "On-Vehicle Inspection and Adjustment"
1
1
CLUTCH LINE (Air in line) .CL-7, "Bleeding"
2
1
tion. If necessary, repair or replace these parts.
MASTER CYLINDER PISTON CUP (Damaged) CL-9, "Disassembly and Assembly".
3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11, "Removal and Installation".
4
2
ENGINE MOUNTING (Loose) EM-102, "Removal and Installation".
1
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-13, "Removal and Installation"
1
CLUTCH DISC (Out of true) CL-15, "Removal and Installation".
5
CLUTCH DISC (Runout is excessive) CL-15, "Removal and Installation".
5
2
CLUTCH DISC (Lining broken) CL-15, "Removal and Installation".
5
CLUTCH DISC (Dirty or burned) CL-15, "Removal and Installation".
5
CLUTCH DISC (Oily) CL-15, "Removal and Installation".
5
2
2
CLUTCH DISC (Worn out) CL-15, "Removal and Installation".
2
2
CLUTCH DISC (Hardened) CL-15, "Removal and Installation".
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CLUTCH DISC (Lack of spline grease) CL-15, "Removal and Installation".
5
DIAPHRAGM SPRING (Damaged) CL-15, "Removal and Installation".
6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-15, "Removal and Installation".
6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion) CL-15, "Removal and Installation".
7
4
FLYWHEEL (Distortion) EM-135, "FLYWHEEL DEFLECTION".
5
PFP:00003
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ACS004O1
CLUTCH PEDAL
CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ACS004O2
1. Check to see if the 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 clevis pin is not free, check that the ASCD clutch switch is
not applying pressure to the clutch pedal causing the clevis pin
to bind. To adjust, loosen lock nut and turn ASCD clutch switch.
CL
b. Tighten the lock nut.
c. Verify that the clevis pin floats in the bore of the clutch pedal. It
should not be bound by the clutch pedal. D
d. If the clevis pin is still not free, remove the clevis pin and check
for deformation or damage. Replace clevis pin if necessary. PCIB0680E
Leave pin removed for step 2.
E
2. Check clutch pedal stroke for free range of movement.
a. With the clevis pin removed, manually move the clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal bracket, assist spring, bushing etc.) Re- F
assemble the clutch pedal and re-verfity that the clevis pin floats freely in the bore of the clutch pedal.
3. Adjust clearance "C" while depressing clutch pedal fully.(With
clutch interlock switch)
G
Clearance C : 0.1 - 1.0mm (0.004 - 0.039 in)
4. Check clutch hydraulic and system components (clutch master H
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as I
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "Bleeding" . J
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 K
purge all the air from the system.
L
SCL800
M
CL-5
CLUTCH PEDAL
Removal and Installation ACS004O3
PCIB0699E
1. Clutch interlock switch 2. Bracket 3. Clevis pin
4. Pedal stopper rubber 5. Clutch pedal 6. Stopper rubber
7. Pedal pad 8. ASCD clutch switch 9. Bushing
10. Snap pin
NOTE:
Tighten the ASCD clutch switch lock nut to the specified torque after installing the clutch pedal assembly in the
vehicle and adjusting the pedal height.
REMOVAL
1. Remove kicking plate. Refer to EI-32, "Removal and Installation" .
2. Remove foot-rest (driver). Refer to EI-36, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-32, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-62, "Removal and Installation"
.
6. Remove the clutch interlock switch and ASCD clutch switch connector and harness.
7. Remove the snap pin and clevis pin.
8. Remove the pedal bracket mounting bolt and nuts and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal assembly.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
q Install clutch pedal assembly and adjust the pedal height. Tighten ASCD clutch switch lock nut to the
specified torque.
q After installing the clutch interlock switch, adjust the switch position.
CL-6
CLUTCH FLUID
CLUTCH FLUID PFP:00017
A
Bleeding ACS004O4
CAUTION:
q Monitor fluid level in the reservoir tank to make sure it does not empty. B
q Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
NOTE: CL
Do not use a vacuum assist or any other type of power bleeder on this system. Use of vacuum assist or power
bleeder will not purge all the air from the system.
1. Fill the master cylinder reservoir tank with new clutch fluid. D
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal quickly and fully a few times and hold
it. E
4. With clutch pedal depressed, open air bleeder.
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds. F
7. Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
8. Tighten air bleeder to the specified torque. Refer to CL-11, SCIA2556J
G
"Removal and Installation" .
H
I
J
K
L
M
CL-7
CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER PFP:30610
Removal and Installation ACS004O5
PCIB0759E
1. Nipple 2. Clamp 3. Reservoir hose
4. Cylinder body 5. Packing 6. Seat
7. Clevis 8. Clevis pin 9. Snap pin
10. Stopper ring 11. Stopper 12. Push rod
13. Piston assembly 14. Return spring 15. Reservoir seal
16. Spring pin
REMOVAL
1. Remove kicking plate. Refer to EI-32, "Removal and Installation" .
2. Remove foot-rest (driver).Refer to EI-36, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-32, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation"
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-62, "Removal and Installation"
.
6. Remove snap pin and clevis pin from the clevis, and separate it from clutch pedal.
7. Remove clips, and remove hoodledge cover.
8. Drain clutch fluid in the reservoir tank and remove reservoir hose from nipple.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
9. Remove the reservoir tank mounting nuts and then remove the
reservoir tank.
10. Using a flare nut wrench, remove clutch tube.
11. First remove nuts on master cylinder assembly, and then master
cylinder assembly from the vehicle.
SCIA1587E
CL-8
CLUTCH MASTER CYLINDER
INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut. A
2. Install master cylinder assembly and tighten mounting nuts to the specified torque. Refer to CL-8,
"Removal and Installation" .
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Refer to CL-12, B
"Removal and Installation" .
4. Install clevis to the clutch pedal, and fix clevis with clevis pin.
5. Install snap pin to the clevis pin. CL
6. Install reservoir hose to the nipple. Install the reservoir tank to the vehicle, and then tighten mounting nuts
to the specified torque.
D
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