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CLUTCH
C TRANSMISSION/TRANSAXLE
A
SECTION CL CLUTCH
B
CL
D
E
CONTENTS
PRECAUTIONS ......................................................... 2
. REMOVAL .......................................................... 11
. F
Service Notice or Precautions ................................. 2 . INSTALLATION .................................................. 12 .
PREPARATION .......................................................... 3
. Disassembly and Assembly ................................... 12 .
Special Service Tools .............................................. 3
. DISASSEMBLY .................................................. 12 . G
Commercial Service Tools ....................................... 3. INSPECTION AFTER DISASSEMBLY ............... 12 .
NOISE, VIBRATION AND HARSHNESS (NVH) ASSEMBLY ........................................................ 12
.
TROUBLESHOOTING ............................................... 5 . CLUTCH PIPING ...................................................... 13
.
H
NVH Troubleshooting Chart .................................... 5 . Removal and Installation ....................................... 13 .
CLUTCH PEDAL ....................................................... 6
. CLUTCH RELEASE MECHANISM .......................... 14 .
On-Vehicle Inspection and Adjustment ................... 6 . Removal and Installation ....................................... 14 .
Removal and Installation ......................................... 7
. COMPONENTS .................................................. 14 . I
COMPONENTS ................................................... 7. REMOVAL .......................................................... 14
.
REMOVAL ............................................................ 7
. INSPECTION AFTER REMOVAL ...................... 15 .
INSPECTION AFTER REMOVAL ........................ 7 . INSTALLATION .................................................. 15 . J
INSTALLATION .................................................... 7
. CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 17 ...
CLUTCH FLUID ......................................................... 8
. Removal and Installation ....................................... 17 .
Air Bleeding Procedure ........................................... 8
. COMPONENTS .................................................. 17 .
K
CLUTCH MASTER CYLINDER ................................. 9 . REMOVAL .......................................................... 17
.
Components ............................................................ 9
. INSPECTION AND ADJUSTMENT AFTER
Removal and Installation ......................................... 9
. REMOVAL .......................................................... 17
.
REMOVAL ............................................................ 9
. INSTALLATION .................................................. 18 . L
INSTALLATION .................................................... 9
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 20 .
Disassembly and Assembly .................................. 10 . Clutch Control System ........................................... 20 .
DISASSEMBLY .................................................. 10
. Clutch Master Cylinder .......................................... 20 . M
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Operating Cylinder ..................................... 20 .
ASSEMBLY ........................................................ 10
. Clutch Disc ............................................................ 20
.
OPERATING CYLINDER ..........................................11 . Clutch Cover .......................................................... 20
.
Components ...........................................................11
. Clutch Pedal .......................................................... 20
.
Removal and Installation ........................................11
.
CL-1
PRECAUTIONS
PRECAUTIONS PFP:00001
Service Notice or Precautions ECS00ICC
q Recommended clutch fluid is brake fluid "DOT 3" or "DOT 4". Refer to MA-14, "RECOMMENDED FLUIDS
AND LUBRICANTS" .
q Do not reuse drained clutch fluid.
q Be careful not to splash clutch fluid on painted areas.
q Use a flare nut wrench, when removing and installing clutch pip-
ing.
q Use new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
q Do not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.
SBR820BA
CL-2
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ECS00ICD
Tool number
Description
Tool name B
KV30101400 Installing release bearing
Drift
a: 51 mm (2.01 in) dia. CL
b: 44 mm (1.73 in) dia.
D
ZZA0838D
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover
E
F
ZZA0508D
KV30100100 Installing clutch disc G
Clutch aligning bar
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.
H
ZZA1178D
I
Commercial Service Tools ECS00ICE
Tool name Description J
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin
K
L
ZZA0515D
GG94310000 Removing and installing clutch piping
Flare nut torque wrench M
a: 10 mm (0.39 in)
S-NT406
CL-3
PREPARATION
Tool name Description
Flare nut torque wrench Removing and installing clutch piping (For
a: 14 mm (0.55 in) LHD models)
S-NT406
Puller Removing release bearing
NT077
CL-4
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 (Inspection and adjustment) CL-6
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-106
1
CL-5
RELEASE BEARING (Worn, dirty or damaged) CL-14
1
CLUTCH DISC (Out of true)
5
CLUTCH DISC (Runout is excessive)
5
2
CLUTCH DISC (Lining broken)
5
CLUTCH DISC (Dirty or burned)
5
CLUTCH DISC (Oily)
5
2
2
CLUTCH DISC (Worn out) CL-17
2
2
CLUTCH DISC (Hardened)
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CLUTCH DISC (Lack of spline grease)
5
DIAPHRAGM SPRING (Damaged)
6
3
DIAPHRAGM SPRING (Out of tip alignment)
6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion)
7
4
FLYWHEEL (Distortion) EM-134
5
PFP:00003
ECS00ICF
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
I
J
L
F
K
E
B
A
CL
H
D
G
M
CLUTCH PEDAL
CLUTCH PEDAL PFP:46540
On-Vehicle Inspection and Adjustment ECS00ICG
1. Make sure that clevis pin floats freely in the bore of clutch pedal.
It should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten lock nut.
c. Make sure that clevis pin floats in the bore of clutch pedal. It
should not be bound by clutch pedal.
d. If clevis pin is still not free, remove clevis pin and check for PCIB0907E
deformation or damage. Replace clevis pin if necessary. Leave
the pin removed for step 2.
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 found, replace related parts (clutch pedal bracket, assist spring, bushing etc.) Re-assem-
ble clutch pedal and again make sure that clevis pin floats freely in the bore of clutch pedal.
3. Adjust clearance "C" while depressing clutch pedal fully. (With
clutch interlock switch)
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding is found, repair or replace related parts
as necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .
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
purge all the air from the system.
SCL800
CL-6
CLUTCH PEDAL
Removal and Installation ECS00ICH
COMPONENTS A
B
CL
D
E
F
PCIB1387E G
1. Clutch pedal assembly 2. Clevis pin 3. Bushing
4. Stopper rubber 5. Pedal stopper bolt (Without ASCD) 6. ASCD clutch switch (With ASCD)
7. Pedal pad 8. Stopper rubber 9. Snap pin H
10. Clutch interlock switch 11. Bushing 12. Assist spring
REMOVAL
I
1. Disconnect clutch interlock switch and ASCD clutch switch (with ASCD) harness connectors.
2. Remove snap pin and clevis pin from clevis of clutch master cylinder.
3. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the J
vehicle.
INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, K
replace clutch pedal.
q Check assist spring for settling. If settling is found, replace assist spring.
L
INSTALLATION
Installation is the reverse order of removal.
NOTE:
M
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.
CL-7
CLUTCH FLUID
CLUTCH FLUID PFP:00017
Air Bleeding Procedure ECS00ICI
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 purge all the air from the system.
CAUTION:
q Monitor clutch fluid level in reservoir tank to make sure it
does not empty.
q Keep painted surface on the body or other parts free of
clutch fluid. If it spills, wipe up immediately and wash the
affected area with water.
q For RHD models: Bleed air for operating cylinder.
q For LHD models: Bleed air for clutch connector first, and then for
operating cylinder.
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve. PCIB1601E
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-11,
"Components" and CL-13, "Removal and Installation" . PCIB1390E
CL-8
CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER PFP:30610
A
Components ECS00ICJ
B
CL
D
E
F
G
PCIB1388E
1. Nipple 2. Clamp 3. Hose
4. Cylinder body 5. Dust cover 6. Clevis H
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin I
Removal and Installation ECS00ICK
REMOVAL
1. Using one of the following methods, remove hose from nipple. J
q Drain clutch fluid from reservoir tank and then remove hose.
q Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping. K
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. L
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
M
4. Remove master cylinder assembly mounting nuts, and then remove master cylinder assembly from the
vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
Length "L"
RHD models : 111.0 mm (4.37 in)
LHD models : 120.5 mm (4.74 in)
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-9, "Components" . SCIA5158E
4. Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-13, "Removal and Installation" .
5. Set clevis to clutch pedal and insert clevis pin.
CL-9
CLUTCH MASTER CYLINDER
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer to CL-6, "On-Vehicle Inspection and Adjustment" and CL-8, "Air Bleeding Proce-
dure" .
Disassembly and Assembly ECS00ICL
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove dust cover from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly PCIB0274E
popping out.
6. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
q Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
q Damaged or deformed nipple or reservoir tank
q Settling of return spring
q Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup. Insert return spring and piston assembly to cylinder body.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install dust cover to cylinder body.
4. Install seal and nipple to cylinder body.
5. Install spring pin using a pin punch.
6. Install clevis to push rod.
7. Check and adjust the positions of clevis and push rod. After
adjusting "L", tighten lock nut to the specified torque. Refer to
CL-9, "Components" .
Length "L"
RHD models : 111.0 mm (4.37 in)
LHD models : 120.5 mm (4.74 in)
SCIA5158E
CL-10
OPERATING CYLINDER
OPERATING CYLINDER PFP:30620
A
Components ECS00ICM
RHD models
B
CL
D
E
F
G
PCIB1602E
1. Air bleeder valve 2. Copper washer 3. Clutch hose
H
4. Cylinder body 5. Dust cover 6. Push rod
7. Piston assembly 8. Piston cup 9. Piston spring
LHD models I
J
K
L
M
PCIB1606E
1. Air bleeder valve 2. Copper washer 3. Union bolt
4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring
Removal and Installation ECS00ICN
REMOVAL
1. Drain clutch fluid.
CL-11
OPERATING CYLINDER
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch hose from operating cylinder assembly.
3. Remove operating cylinder assembly mounting bolts, and then remove operating cylinder assembly from
the vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal.
q Install clutch hose with care so that it will not be bent or twisted.
q Tighten clutch hose to the specified torque.
CAUTION:
Do not reuse copper washer.
q After completing the procedure, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleed-
ing Procedure" .
Disassembly and Assembly ECS00ICO
DISASSEMBLY
q Remove dust cover and push rod. Then remove piston, piston cup and piston spring from cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
q Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
q Settling of piston spring
q Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and then install push rod and dust cover.
CL-12
CLUTCH PIPING
CLUTCH PIPING PFP:30650
A
Removal and Installation ECS00ICP
RHD models
B
CL
D
PCIB1651E E
1. Clutch tube 2. Clutch orifice 3. Lock plate
4. Clutch hose 5. Operating cylinder 6. Master cylinder
7. Clutch pedal F
LHD models
G
H
I
PCIB1605E
1. Clutch tube 2. Clutch orifice 3. Lock plate
J
4. Clutch hose 5. Operating cylinder 6. Clutch tube
7. Clutch connector 8. Air bleeder valve 9. Master cylinder
K
10. Clutch pedal
Carefully observe the following steps during clutch tube removal and installation.
L
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
q To fix clutch hose on bracket, position clutch hose clasp on the M
emboss of bracket and drive lock plate vertically from above. Be
careful not to bend or twist clutch hose. Do not scratch or dam-
age clutch hose.
q Tighten clutch tube flare nut to the specified torque.
q Tighten clutch hose or union bolt to the specified torque.
CAUTION:
Do not reuse copper washer.
q After installation, bleed the air from the clutch hydraulic system.
Refer to CL-8, "Air Bleeding Procedure" . PCIB0681E
CL-13
CLUTCH RELEASE MECHANISM
CLUTCH RELEASE MECHANISM PFP:30502
Removal and Installation ECS00ICQ
COMPONENTS
PCIB1615E
1. Holder spring 2. Release bearing sleeve 3. Release bearing
4. Snap spring 5. Dust cover 6. Withdrawal lever
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-16, "Removal and Installation from Vehicle" .
2. Remove release bearing sleeve assembly, holder spring and withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove snap spring from withdrawal lever.
5. Remove release bearing from release bearing sleeve using a
puller.
CLA0013D
CL-14
CLUTCH RELEASE MECHANISM
INSPECTION AFTER REMOVAL
q If release bearing is seized, damaged, not properly centered or A
does not rotate smoothly, replace it.
q If contact surface of withdrawal lever is excessively worn,
replace it. B
q If dust cover is cracked, replace it.
CL
SCIA1660E
D
INSTALLATION
CAUTION: E
q Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
F
q Be careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel
surface.
1. Install release bearing to release bearing sleeve using the drift.
G
Tool number : KV30101400
CAUTION:
Press bearing inner race by pushing with the drift. H
I
PCIB0275E
J
2. Following the instructions below, apply grease to the specified points.
K
L
M
PCIB1393E
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
q Evenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.
q Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bear-
ing sleeve. The grease surface should be level with the surrounding area.
q Apply a thin coat of recommended grease evenly to release bearing sleeve sliding surface of front
cover. Install release bearing sleeve assembly to front cover. Wipe off any excess grease that oozes
from the parts and then remove release bearing sleeve assembly.
3. To install, reverse the removal procedure, following the cautions below.
CAUTION:
q Before installing manual transmission to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.
CL-15
CLUTCH RELEASE MECHANISM
q When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever.
q Be careful with the orientation snap spring.
SCIA6903E
CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100
A
Removal and Installation ECS00ICR
COMPONENTS
B
CL
D
E
F
G
PCIB1394E
1. Flywheel 2. Clutch disc 3. Clutch cover
H
CAUTION:
q Be careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel
surface.
I
q If the flywheel is removed, align the dowel pin with smallest hole of flywheel. Refer to EM-114,
"ASSEMBLY" .
REMOVAL J
1. Remove manual transmission from the vehicle. Refer to MT-16, "Removal and Installation from Vehicle" .
2. Loosen clutch cover mounting bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL K
Clutch Disc
q Measure circumferential runout relative to clutch disc center L
spline. If it is outside the specification, replace clutch disc.
Runout limit/diameter of the area to be measured
: 1.0 mm (0.039 in)/230 mm (9.06 in) dia. M
q Measure backlash to clutch disc spline and main drive gear
spline at the circumference of clutch disc. If outside the specifi-
cation, replace clutch disc.
Maximum allowable spline backlash
: 1.0 mm (0.039 in) SCL221
CL-17
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
q Measure the depth to clutch disc facing rivet heads using a cali-
pers. If it exceeds the allowable wear limit, replace clutch disc.
Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)
SCL229
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
Tolerance for diaphragm spring lever unevenness
: 0.7 mm (0.028 in) or less
Tool number : ST20050240
q Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE: PCIB0276E
q Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.
q Broken thrust ring will make a clinking sound when cover is shaken up and down.
q If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Measure the runout at the flywheel clutch contact surface using a
dial indicator. If runout is outside the specification, replace flywheel.
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
Allowable flywheel runout
: Refer to EM-134, "FLYWHEEL DEFLECTION" .
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
PBIC2646E
INSTALLATION
1. Apply recommended grease to clutch disc and main drive gear splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
CL-18
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
2. Install clutch disc using the clutch aligning bar.
A
Tool number : KV30100100
3. Install clutch cover. Pre-tighten clutch cover mounting bolts.
4. Tighten clutch cover mounting bolts evenly in two steps in the B
order shown in the figure. Refer to CL-17, "COMPONENTS" .
5. Install manual transmission. Refer to MT-16, "Removal and
Installation from Vehicle" . CL
D
E
F
G
PCIB1630E
H
I
J
K
L
M
CL-19
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Clutch Control System ECS00ICS
Type of clutch control Hydraulic
Clutch Master Cylinder ECS00ICT
Inner diameter 15.87 mm (5/8 in)
Clutch Operating Cylinder ECS00ICU
Inner diameter 19.05 mm (3/4 in)
Clutch Disc ECS00ICV
Facing size (outer dia. x inner dia. x thickness) 240 mm ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo