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CLUTCH

C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
PRECAUTIONS ......................................................... 2 . CSC (CONCENTRIC SLAVE CYLINDER) ................. 9 . F
Caution .................................................................... 2
. Removal and Installation ......................................... 9 .
PREPARATION .......................................................... 3. REMOVAL ............................................................ 9
.
Special Service Tools .............................................. 3 . INSPECTION ....................................................... 9
. G
NOISE, VIBRATION AND HARSHNESS (NVH) INSTALLATION .................................................... 9.
TROUBLESHOOTING ............................................... 4 . CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 10 ...
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 10 .
H
CLUTCH ............................................................... 4
. REMOVAL .......................................................... 11
.
CLUTCH PEDAL ....................................................... 5 . INSPECTION AND ADJUSTMENT AFTER
On Board Inspection ............................................... 5 . REMOVAL (CR ENGINE) ................................... 11 .
HEIGHT INSPECTION ......................................... 5 . INSPECTION AND ADJUSTMENT AFTER I
PLAY INSPECTION ............................................. 5 . REMOVAL (K9K ENGINE) ................................. 12 .
CLEARANCE CHECK .......................................... 5 . INSTALLATION .................................................. 12 .
Removal and Installation ......................................... 6 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 14 . J
REMOVAL ............................................................ 6
. Clutch Pedal .......................................................... 14
.
INSPECTION AFTER REMOVAL ........................ 6 . Clutch Disc ............................................................ 14
.
INSTALLATION .................................................... 6 . Clutch Cover .......................................................... 14
.
K
CLUTCH FLUID ......................................................... 7. Clutch Control System ........................................... 14 .
Air Bleeding Procedure ........................................... 7 . Clutch Master Cylinder .......................................... 14 .
CLUTCH MASTER CYLINDER ................................. 8 .
Removal and Installation ......................................... 8 . L
REMOVAL ............................................................ 8
.
INSTALLATION .................................................... 8 .
M

CL-1
PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ECS008JC

q Recommended fluid is brake fluid "DOT 3" or "DOT 4". Refer to MA-18, "Fluids and Lubricants".
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas.
q Use new brake fluid to clean or wash all parts of master cylinder and concentric slave cylinder.
q Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.
q If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder).
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts
may damage CSC seal and may cause fluid leak.
q Do not disassemble master cylinder and CSC.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-2
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS008JD

Tool number Description
(Renault tool number) B
Tool name

KV10110910 Removing and Installing clutch
Ring gear stopper cover and flywheel CL
(For CR engine)

ZZA1005D

KV113B0060 Removing and Installing clutch E
(Mot. 582-01) cover and flywheel
Ring gear stopper
(For K9K engine)
F

YCL036
G
ST20050240 Inspecting diaphragm spring of
Diaphragm spring adjusting wrench clutch cover

ZZA0508D I
EM07020000 Installing clutch cover and disc
Clutch aligner
J

K
PCIB0017E

CL-3
CLUTCH

Symptom
Reference page

Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
NVH Troubleshooting Chart

Clutch does not disengage
CLUTCH PEDAL (Free play out of 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-8.

3
2
ENGINE MOUNTING (Loose) EM-69 .

CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-9

1
CLUTCH DISC (Out of true) CL-10.

4
CLUTCH DISC (Runout is excessive) CL-10.

4
2
CLUTCH DISC (Lining broken) CL-10.

4
CLUTCH DISC (Dirty or burned) CL-10.

4
CLUTCH DISC (Oily) CL-10.

4
2
2

2 CLUTCH DISC (Worn out) CL-10.
2

CLUTCH DISC (Hardened) CL-10
2

CLUTCH DISC (Lack of spline grease) CL-10
4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DIAPHRAGM SPRING (Damaged) CL-12.
5
3

DIAPHRAGM SPRING (Out of tip alignment) CL-12.
5
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion) CL-12.
6
4

FLYWHEEL (Distortion) CL-10
5
PFP:00003

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ECS008SM
CLUTCH PEDAL

CLUTCH PEDAL SMA for VIN >SJN**AK12U1107568 PFP:46540
A
On Board Inspection ECS008JE

HEIGHT INSPECTION
1. Make sure clutch pedal height H1 from upper surface of the
B
dash panel is within the specified range.
Pedal height H1
: 164 - 174 mm (6.46 - 6.85 in) (CR engine) CL
: 160 - 169 mm (6.30 - 6.65 in) (LHD with K9K engine)
: 164 - 173 mm (6.46 - 6.81 in) (RHD with K9K engine)
D
2. If pedal height H1 is outside the specification, replace pedal
assembly.
3. Make sure free play A at pedal pad top surface and pedal height E
H2 when clutch is disengaged are within the ranges specified
below.
A: Pedal free play at the pedal pad F
: 2 - 8 mm (0.08 - 0.31 in) (CR engine)
: 5 mm (0.20 in) (K9K engine)
G
Pedal height H2 when clutch is disengaged
: 100 mm (3.94 in) or more (CR engine)
4. If free play A at pedal pad top surface and pedal height H2 when H
clutch is disengaged are outside the specification, replace clutch SCIA1256E
pedal assembly.
PLAY INSPECTION I
q Press the clutch pedal by hand until certain resistance can be
felt. Using a scale, Make sure the free play is within the specified
range. J
Pedal free play
: 2 - 8 mm (0.08 - 0.31 in) (CR engine)
K
: 5 mm (0.20 in) (K9K engine)

L
MAA0023D

CLEARANCE CHECK
M
1. Start the engine and let it idle.
2. Apply parking brake.
3. Depress the brake pedal.
4. Fully depress clutch pedal and shift to 1st gear.
5. Release clutch pedal gradually. Using a scale, check the clear-
ance between the clutch pedal and floor panel to see if it is
within the specified range.
Pedal height when the clutch disengages
: 100 mm (3.94 in) or more (CR engine)
MAA0024D
NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point. Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify the inspection.

CL-5
CLUTCH PEDAL

Removal and Installation ECS008JF

REMOVAL
1. Remove instrument panel under tray. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
2. Unlock master cylinder rod end and separate master cylinder
from clutch pedal.
3. Remove clutch switch harness clamp from pedal bracket.
4. Disconnect clutch switch connector.

SCIA1284E

5. Remove nuts (3), and remove clutch pedal assembly.

SCIA1260E

INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, and a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly.
INSTALLATION
q Install in the reverse order of removal.

CL-6
CLUTCH FLUID

CLUTCH FLUID PFP:00017
A
Air Bleeding Procedure ECS008JG

CAUTION:
q Monitor fluid level in the reservoir tank to make sure it does not empty. B
q Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
q Bleed the bleeding connector. CL
1. Fill the master cylinder reservoir tank with new brake fluid.
2. Remove rubber cap and connect a transparent vinyl hose to air
bleeder of bleeding connector. D

SCIA1261E

G
3. Lift tube side lock pin of bleeding connector up one step.
CAUTION:
Do not remove lock pin. H
4. "Depress" and "release" the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and hold it.
CAUTION: I
Hold it to prevent releasing tube from bleeding connector
when fluid pressure is applied in the tube.
J
SCIA1262E

5. Slide tube 5 mm (0.20 in) to the direction shown by the arrow K
and drain clutch fluid.
6. Return tube to its original position.
7. Release clutch pedal and wait for 5 seconds. L
8. Repeat steps 4 to 7 until no bubbles can be observed in the
brake fluid.
M

SCIA1263E

CL-7
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ECS008JH

REMOVAL
1. Drain brake fluid from reservoir tank and remove hose from the nipple.
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Unlock master cylinder rod end in the passenger room and sep-
arate master cylinder from clutch pedal.

SCIA1284E

3. Remove lock pin from master cylinder and separate clutch tube.
4. Rotate master cylinder clockwise by 45

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