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CLUTCH


C TRANSMISSION/TRANSAXLE

                                                                                                                                                                 A


                                                                                                                                                                 B
                                                                                                     SECTION
                                                                                                                                    CLUTCH                       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                                                                 ACS003LR


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                                                                                        ACS003LS

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                                                                                     ACS003LT
                                                                                                                         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, "Disassembly and Assembly".




       4
                                                                 2
                                                                                                               ENGINE MOUNTING (Loose)                                    EM-104, "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-137, "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-
                                                                                                                                                                                                                                                                                                                                                    ACS003LU
                                              CLUTCH PEDAL

CLUTCH PEDAL                                                                                              PFP:46540
                                                                                                                         A
On-Vehicle Inspection and Adjustment                                                                          ACS003LV


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                                                                                    ACS003LW




                                                                                                      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 front kicking plate. Refer to EI-39, "Removal and Installation" .
2.    Remove foot-rest (driver). Refer to EI-43, "Removal and Installation" .
3.    Remove dash side finisher. Refer to EI-39, "Removal and Installation" .
4.    Remove instrument lower driver panel. Refer to IP-10, "Component Parts Drawing" .
5.    Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-66, "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                                                                                              ACS003LX


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                                                                           ACS003LY




                                                                                            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 front kicking plate. Refer to EI-39, "Removal and Installation" .
2.    Remove foot-rest (driver).Refer to EI-43, "Removal and Installation" .
3.    Remove dash side finisher. Refer to EI-39, "Removal and Installation" .
4.    Remove instrument lower driver panel. Refer to IP-10, "Component Parts Drawing"
5.    Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer toBRC-66, "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
             : 5.8 N



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