Drive Train

CLUTCH

Driven Disc and Pressure Plate

Fig. 1: Clutch system components-mechanical clutch

Fig. 2: Clutch system components-hydraulic clutch

Fig. 3: View of the clutch and pressure plate assembly

Fig. 4: Removing the clutch and pressure plate bolts

Fig. 5: Removing the clutch and pressure plate assembly

Fig. 6: Removing the clutch and pressure plate

Fig. 7: View of the flywheel once the clutch assembly is removed

Fig. 8: Removing the flywheel bolts. Be sure to lock the flywheel in place

Fig. 9: Removing the flywheel from the crankshaft

Fig. 10: Add a thread locking agent to the flywheel bolts upon installation

Fig. 11: Be sure that the flywheel surface is clean, before installing the clutch

Fig. 12: Check across the flywheel surface, it should be flat

Fig. 13: Checking the pressure plate for excessive wear

Fig. 14: View of the clutch alignment arbor, used to install the clutch and pressure plate assembly

Fig. 15: Install a clutch alignment arbor, to align the clutch assembly during installation

Fig. 16: Clutch plate installed with the arbor in place

Fig. 17: Pressure plate-to-flywheel bolt hole should align

Fig. 18: Install locking agent to clutch assembly bolts

Fig. 19: Be sure to use an torque wrench to tighten all bolts

Fig. 20: Grease the clutch release fork ball

Fig. 21: View of the clutch release fork, check this for signs of damage

Fig. 22: View of the clutch release fork bearing clips, make sure these are not bent or broken

Fig. 23: Removing the clutch release fork bearing clips

Fig. 24: Grease the throwout bearing assembly at the outer contact points

Fig. 25: Grease the throwout bearing assembly at the inner contact points

Fig. 26: Installing the clutch release fork bearing clip

Fig. 27: View of the clutch release fork assembly installed, be sure all parts move freely

1. Disconnect the negative battery cable. Remove the transaxle as outlined earlier in this section.
2. Gradually unscrew the six bolts (6mm) which hold the pressure plate assembly on the flywheel. Loosen the bolts only one turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time.
3. When all of the bolts have been removed, remove the clutch plate and disc.

4. Remove the two retaining springs and remove the throwout bearing and the release fork.

Do not disassemble either the clutch cover or disc. Inspect the parts for wear or damage and replace any parts as necessary. Replace the clutch disc if there is any oil or grease on the facing. Do not wash or attempt to lubricate the throwout bearing. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.

To install:

5. Fit the release fork boot on the front of the transaxle housing. Install the release fork.
6. Insert the throwout bearing assembly and secure it with the two springs. Coat the inside diameter of the bearing holder and the fork-to-holder contact points with grease.
7. Insert a pilot shaft through the clutch cover and disc, then insert the end of the pilot into the needle bearing.
8. Tighten the pressure plate bolts gradually, one turn at a time, until the proper torque is reached. Tighten to 12.7 ft. lbs. (17.2 Nm).

9. After installation of the transaxle in the car, perform the adjustments outlined above.

END OF SECTION