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CLUTCH
C TRANSMISSION/TRANSAXLE
A
SECTION CL CLUTCH
B
CL
D
E
CONTENTS
RS6F51R OPERATING CYLINDER ......................................... 11 . F
Removal and Installation ....................................... 11 .
PRECAUTIONS ......................................................... 2 . REMOVAL .......................................................... 11
.
Caution .................................................................... 2
. INSTALLATION .................................................. 11 . G
PREPARATION .......................................................... 3. Disassembly and Assembly ................................... 11 .
Special Service Tools .............................................. 3 . DISASSEMBLY .................................................. 11 .
Commercial Service Tool ........................................ 3 . INSPECTION AFTER DISASSEMBLY ............... 11 .
NOISE, VIBRATION AND HARSHNESS (NVH) H
ASSEMBLY ........................................................ 12
.
TROUBLESHOOTING ............................................... 4 . CLUTCH PIPING ...................................................... 13
.
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 13 .
CLUTCH PEDAL ....................................................... 5 . CLUTCH RELEASE MECHANISM .......................... 14 . I
On-Vehicle Inspection and Adjustment ................... 5 . Removal and Installation ....................................... 14 .
CLUTCH PEDAL STROKE INSPECTION ........... 5 . REMOVAL .......................................................... 14
.
CLUTCH PEDAL FREE PLAY INSPECTION ...... 5 . INSPECTION AFTER REMOVAL ...................... 14 . J
CLUTCH PEDAL STROKE ADJUSTMENT ......... 5 . INSTALLATION .................................................. 14 .
CLUTCH PEDAL FREE PLAY ADJUSTMENT ..... 6 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 16 ...
Removal and Installation ......................................... 6 . Removal and Installation ....................................... 16 .
INSPECTION AFTER REMOVAL ........................ 7 . K
REMOVAL .......................................................... 16
.
CLUTCH FLUID ......................................................... 8. INSPECTION AND ADJUSTMENT AFTER
Air Bleeding Procedure ........................................... 8 . REMOVAL .......................................................... 16
.
CLUTCH MASTER CYLINDER ................................. 9 . INSTALLATION .................................................. 17 . L
Removal and Installation ......................................... 9 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 18 .
REMOVAL ............................................................ 9
. Clutch Control System ........................................... 18 .
INSTALLATION .................................................... 9 . Clutch Master Cylinder .......................................... 18 . M
Disassembly and Assembly .................................. 10 . Clutch Operating Cylinder ..................................... 18 .
DISASSEMBLY .................................................. 10 . Clutch Disc ............................................................ 18
.
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Cover .......................................................... 18
.
ASSEMBLY ........................................................ 10 . Clutch Pedal .......................................................... 18
.
CL-1
PRECAUTIONS
[RS6F51R]
PRECAUTIONS
[RS6F51R] PFP:00001
Caution ECS0094X
q Recommended fluid is brake fluid "DOT 3" or "DOT 4".
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 SBR686C
use compressed air.
CL-2
PREPARATION
[RS6F51R]
PREPARATION PFP:00002
A
Special Service Tools ECS0094Y
Tool name
Description
Tool number B
Pin punch
CL
Removing and installing master cylinder
ST23550000
spring pin
Tip diameter: 4.5 mm (0.177 in) dia.
D
ZZA0515D
E
Diaphragm adjusting wrench Adjusting unevenness of diaphragm spring of
ST20050240 clutch cover
F
ZZA0508D
G
Clutch aligning bar
ST20630000
a: 15.8 mm (0.622 in) dia. Installing clutch cover and disc H
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.077 in)
S-NT405
I
Commercial Service Tool ECS0094Z
Tool name Description J
1. Flare nut crowfoot K
2. Torque wrench Removing and installing clutch piping
a: 10 mm (0.39 in)
L
S-NT360
M
CL-3
Symptom
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 (Free play out of adjustment) CL-5
1
1
CLUTCH LINE (Air in line) CL-8
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-197
1
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-14
1
CLUTCH DISC (Out of true) CL-16
5
CLUTCH DISC (Runout is excessive) CL-16
5
2
CLUTCH DISC (Lining broken) CL-16
5
CLUTCH DISC (Dirty or burned) CL-16
5
CLUTCH DISC (Oily) CL-16
5
2
2
CLUTCH DISC (Worn out) CL-16
2
2
CLUTCH DISC (Hardened) CL-16
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CLUTCH DISC (Lack of spline grease) CL-16
5
DIAPHRAGM SPRING (Damaged) CL-17
6
3
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
DIAPHRAGM SPRING (Out of tip alignment) CL-17
6
2
PRESSURE PLATE (Distortion) CL-17
7
4
FLYWHEEL (Distortion) CL-17
5
[RS6F51R]
PFP:00003
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ECS00950
CLUTCH PEDAL
[RS6F51R]
CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ECS00951
CLUTCH PEDAL STROKE INSPECTION
Check clutch pedal stroke by using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the B
middle of the clutch pedal pad. Place a book/clipboard on the driver's seat to set a reference point, ensure the
book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard. Mea-
sure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified pedal CL
stroke in the table, adjust actual pedal stroke if necessary (refer to CL-5, "CLUTCH PEDAL STROKE
ADJUSTMENT" ).
NOTE: D
q Do not use steering wheel as a reference point, angle gives incorrect reading.
q Ensure there is no interference between the floor carped and clutch pedal when fully depressed.
E
F
G
H
I
J
K
L
NCL058 M
CLUTCH PEDAL FREE PLAY INSPECTION
Check pedal free play, if out of specification refer to CL-5, "CLUTCH
PEDAL STROKE ADJUSTMENT" .
q Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
SCL702
CLUTCH PEDAL STROKE ADJUSTMENT
1. Loosen the pedal stopper bolt completely (so there is on contact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cylinder push rod.
CL-5
CLUTCH PEDAL
[RS6F51R]
3. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free play.
Clutch pedal stroke "S": 155 - 160 mm (6.10 - 6.30 in)
CLUTCH PEDAL FREE PLAY ADJUSTMENT
1. Adjust pedal free play to the specified value with the master cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
q Push on the clutch pedal until resistance is felt, and check the distance the pedal moves.
Pedal free play "A": 1 - 3 mm (0.04 - 0.12 in)
Removal and Installation ECS00952
MCIA0125E
MCIA0126E
1. Clutch pedal assembly 2. Clevis pin 3. Bushing
4. Snap pin 5. Stopper bolt 6. Clutch pedal
NOTE:
Install clutch pedal assembly and adjust the pedal height. Tighten stopper bolt to the specified torque.
CL-6
CLUTCH PEDAL
[RS6F51R]
INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, A
replace the clutch pedal.
q Check assist spring for settling. If settling is found, replace the assist spring.
B
CL
D
E
F
G
H
I
J
K
L
M
CL-7
CLUTCH FLUID
[RS6F51R]
CLUTCH FLUID PFP:00017
Air Bleeding Procedure ECS00953
CAUTION:
q Monitor fluid level in the reservoir to make sure it does not empty.
q Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
q Bleed the operating cylinder.
1. Fill the master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal slowly and fully a few times at an inter-
val of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder.
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 the
brake fluid.
MCIA0127E
Air bleeder
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