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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                                                                 ACS006FX


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                                                                                                              ACS006FZ

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

  KV30101400                                                                             Installing release bearing
                                                                                                                                              CL
  (      --       )
  Drift
  a: 51 mm (2.01 in) dia.
  b: 44 mm (1.73 in) dia.                                                                                                                     D

                                                                        ZZA0838D


  ST20050240                                                                             Adjusting unevenness of diaphragm spring of
                                                                                                                                              E
  (      --      )                                                                       clutch cover
  Diaphragm adjusting wrench
                                                                                                                                              F


                                                                        ZZA0508D
                                                                                                                                              G
  ST20670000                                                                             Installing clutch disc
  (      --        )
  Clutch aligning bar
                                                                                                                                              H
  a: 15 mm (0.59 in) dia.
  b: 23 mm (0.91 in) dia.

                                                                                                                                               I
                                                                        ZZA1178D



Commercial Service Tools                                                                                                           ACS006G0

                                                                                                                                               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


  1. Flare nut crowfoot                                                                  Removing and installing clutch piping                M
  2. Torque wrench
  a: 10 mm (0.39 in)




                                                                         S-NT360


  Power tool                                                                             Loosening bolts and nuts




                                                                         PBIC0190E




                                                                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




       1
                                   1
                                                                                                               CLUTCH LINE (Air in line)                                  CL-7




       2
                                                                 1
                                                                                                                                                                                                      tion. If necessary, repair or replace these parts.




                                                                                                               MASTER CYLINDER PISTON CUP (Damaged)                       CL-9




       3
                                                                 2
                                                                                                               OPERATING CYLINDER PISTON CUP (Damaged)                    CL-11




       4
                                                                 2
                                                                                                               ENGINE MOUNTING (Loose)                                    EM-111




                                                                                       1




CL-4
                                                                                                               RELEASE BEARING (Worn, dirty or damaged)                   CL-13




                                                  1
                                                                                                               CLUTCH DISC (Out of true)                                  CL-15




       5
                                                                                                               CLUTCH DISC (Runout is excessive)                          CL-15




       5
                                                                                       2
                                                                                                               CLUTCH DISC (Lining broken)                                CL-15




       5
                                                                                                               CLUTCH DISC (Dirty or burned)                              CL-15




       5
                                                                                                               CLUTCH DISC (Oily)                                         CL-15



       5
                                   2
                                                                                       2




                                   2                                                                           CLUTCH DISC (Worn out)                                     CL-15
                                                                                       2




                                                                                                               CLUTCH DISC (Hardened)                                     CL-15
                                                                                       2
                                                                                                                                                                                                                                                                                                                     NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING




                                                                                                               CLUTCH DISC (Lack of spline grease)                        CL-15
       5



                                                                                                               DIAPHRAGM SPRING (Damaged)                                 CL-15
       6
                                   3




                                                                                                               DIAPHRAGM SPRING (Out of tip alignment)                    CL-15
       6
                                                                                       2
                                                                                                                                                                                                                                                                                                                                                                            NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING




                                                                                                               PRESSURE PLATE (Distortion)                                CL-15
       7
                                   4




                                                                                                               FLYWHEEL (Distortion)                                      EM-148
                                   5
                                                                                                                                                                                                                                                                                                                                                      PFP:00003



                                                                                                                                                                                                      Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
                                                                                                                                                                                                                                                                                                                       ACS006G1
                                              CLUTCH PEDAL

CLUTCH PEDAL                                                                                          PFP:46540
                                                                                                                     A
On-Vehicle Inspection and Adjustment                                                                      ACS006G2


1.   Check to see if clevis pin floats freely in the bore of clutch pedal.
     It should not be bound by clevis or clutch pedal.                                                             B
a.   If clevis pin is not free, check that ASCD clutch switch is not
     applying pressure to clutch pedal causing clevis pin to bind. To
     adjust, loosen lock nut and turn ASCD clutch switch.
                                                                                                                  CL
b.   Tighten lock nut.
c.   Verify that clevis pin floats in the bore of clutch pedal. It should
     not be bound by clutch pedal.                                                                                 D
d.   If clevis pin is still not free, remove clevis pin and check for
     deformation or damage. Replace clevis pin if necessary. Leave                                      PCIB0680E
     pin removed for step 2.
                                                                                                                   E
2.   Check clutch pedal stroke for free range of movement.
a.   With clevis pin removed, manually move 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 clutch pedal and re-verfity that clevis pin floats freely in the bore of 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                                                                                  ACS006G3




                                                                                                   PCIB0864E

     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

REMOVAL
1.    Remove kicking plate. Refer to EI-39, "Removal and Installation" .
2.    Remove foot-rest. 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-11, "Removal and Installation" .
5.    Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-66, "Removal and Installation"
      .
6.    Remove clutch interlock switch and ASCD clutch switch connector and harness.
7.    Remove snap pin and clevis pin.
8.    Remove pedal bracket mounting bolt and nuts and then remove 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 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 clutch interlock switch, adjust the switch position.
NOTE:
Tighten ASCD clutch switch lock nut to the specified torque after installing clutch pedal assembly in vehicle
and adjusting the pedal height.




                                                      CL-6
                                           CLUTCH FLUID

CLUTCH FLUID                                                                                      PFP:00017
                                                                                                                 A
Bleeding                                                                                              ACS006G4


CAUTION:
q   Monitor fluid level in 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 master cylinder reservoir tank with new clutch fluid.                                                  D
2. Connect a transparent vinyl hose to air bleeder.
3. Depress clutch pedal quickly and fully a few times and hold it.
4. With clutch pedal depressed, open air bleeder.                                                              E
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in brake                                               F
    fluid.
8. Tighten air bleeder to the specified torque. Refer to CL-11,
    "Removal and Installation" .                                                                    SCIA1496E
                                                                                                               G


                                                                                                                 H



                                                                                                                 I


                                                                                                                 J



                                                                                                                 K


                                                                                                                 L



                                                                                                                 M




                                                  CL-7
                                 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER                                                                        PFP:30610

Removal and Installation                                                                            ACS006G5




                                                                                             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-39, "Removal and Installation" .
2.    Remove foot-rest. 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-11, "Removal and Installation" .
5.    Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-66, "Removal and Installation"
      .
6.    Remove snap pin and clevis pin from clevis, and separate it from clutch pedal.
7.    Remove hoodledge cover.
8.    Drain clutch fluid in reservoir tank and remove reservoir hose.
      CAUTION:
      Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
      affected area with water.

9. Remove reservoir tank.
10. Remove clutch tube using a flare nut wrench. Refer to CL-12,
    "Removal and Installation" .
11. Remove master cylinder assembly.




                                                                                                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.    Tighten clutch tube flare nut to the specified torque using a flare nut torque wrench. Refer to CL-12, B
      "Removal and Installation" .
4.    Install clevis to clutch pedal, and fix clevis with clevis pin.
5.    Install snap pin to clevis pin.                                                                        CL
6.    Install reservoir hose to nipple. Install reservoir tank to vehicle,
      and then tighten mounting nuts to the specified torque.
                                                                                                              D
             : 5.8 N



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