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SECTION 5C

CLUTCH

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

DESCRIPTION AND OPERATION

DRIVING MEMBERS

The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel, and the other is the pressure plate. The pressure plate is fitted into a steel cover, which is bolted to the flywheel.

DRIVEN MEMBERS

The driven member is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft, but which drives the input shaft through these same splines.
The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.

OPERATING MEMBERS

The clutch release system consists of the clutch pedal, the clutch release shaft, the clutch cable, the release arm and the release bearing. When pressure is applied to the clutch pedal, the clutch release shaft pushes against the release bearing by rotating. The bearing then pushes against the diaphragm spring in the pressure plate assembly, thereby releasing the clutch.

COMPONENT LOCATOR

CLUTCH COMPONENTS


D13C4011
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  1. Clutch Disc
  2. Pressure Plate
  3. Release Bearing
  4. Release Shaft
  5. Release Shaft Bushing (No.1)
  6. Release Shaft Bushing (No.2)
  7. Release Shaft Seal
  8. Release Arm
  9. Clutch Cable Adjusting Nut
  10. Clutch Cable
  11. Clutch Pedal

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS

Condition
Probable Cause
Correction
Slipping Clutch
  • Improper clutch cable adjustment.
  • Adjust clutch cable.
  • Worn or oily contamination on clutch disc surface.
  • Replace clutch disc.
  • Worn or oily contamination on pressure plate, flywheel surface.
  • Replace pressure plate, flywheel.
  • Damaged or weakened diaphragm spring.
  • Replace pressure plate.
  • Rusted clutch cable.
  • Replace clutch cable.
Dragging Clutch
  • Improper clutch cable adjustment.
  • Adjust clutch cable.
  • Worn or weakened diaphragm spring.
  • Replace pressure plate.
  • Worn or rusted splines of input shaft or clutch disc.
  • Replace input shaft or clutch disc.
  • Excessively wobbly clutch disc.
  • Replace clutch disc.
  • Worn clutch disc.
  • Replace clutch disc.
Fails to Release
  • Bent or damaged clutch disc.
  • Replace clutch disc.
  • Worn or rusted splines of input shaft or clutch disc.
  • Replace input shaft or clutch disc.
  • Improper operation of clutch release shaft.
  • Replace clutch release shaft.
Pedal Stays on Floor When Disengaged
  • Interfered clutch release bearing.
  • Lubricate and adjust clutch release bearing.
  • Weakened diaphragm spring.
  • Replace pressure plate.
Clutch Vibration
  • Clutch facing with oily contamination.
  • Replace clutch disc.
  • Release bearing slides unsmoothly on input shaft bearing retainer.
  • Lubricate retainer release bearing.
  • Wobbly clutch disc or poor facing contact.
  • Replace clutch disc.
  • Loose clutch disc rivets.
  • Replace clutch disc.
  • Weakened clutch disc torsion spring.
  • Replace clutch disc.
  • Distorted pressure plate or flywheel surface.
  • Replace pressure plate or flywheel.
  • Weakened engine mounting or loosened installing bolt or nut.
  • Retighten or replace mounting.
Clutch Noise
  • Worn or broken release bearing.
  • Replace release bearing.
  • Worn input shaft bearing.
  • Replace input shaft bearing.
  • Cracked clutch disc.
  • Replace clutch disc.
  • Pressure plate and diaphragm spring rattling.
  • Replace pressure plate.
  • Improper clutch cable adjustment.
  • Adjust clutch cable.
Grabbing Clutch
  • Clutch disc facing with oily contamination.
  • Replace clutch disc.
  • Excessively worn on clutch disc facing.
  • Replace clutch disc.
  • Rivet head showing out of facing.
  • Replace clutch disc.
  • Weakened clutch torsion spring.
  • Replace clutch disc.

CLUTCH PEDAL OPERATION


D103C301
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Clutch pedal free travel

It is designed that there is no clutch pedal free travel.

Clutch pedal travel (A)

Pedal Travel
100-110 mm (3.9-4.3 in.)

Clearance between pedal and floor just before clutch connection (B)

After starting the engine, check if the clearance between pedal and floor is within specified range in condition of idling, lifting, parking brake and drawing out clutch pedal.
Clearance Between Pedal and Floor just Before Clutch Connection
30-40 mm (1.2-1.6 in.)

Caution : During inspection, take care on sudden departure.

CLUTCH CABLE ADJUSTMENT


D103C302
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If clutch connection / disconnection is operated un-smoothly, adjust the clutch cable by adjusting clutch cable adjust nut.

INSTRUCTION REPAIR

ON-VEHICLE SERVICE



D13B5151
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PRESSURE PLATE, CLUTCH DISC AND INPUT SHAFT BEARING

Tools Required

09917-58010
Input Shaft Bearing Remover
09924-17810
Flywheel Holder
09925-98210
Input Shaft Bearing Installer
DW110-021
Engine Fixture
DW210-010
Clutch Center Guide

Removal Procedure

  1. Remove the transaxle from the vehicle. Refer to Section 5B, Manual Transaxle.


  2. D103B516
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  3. Support the engine to normal position using the engine fixture DW110-021.
  4. Notice : The abnormal position of the engine may damage to the related parts and interfere with them. You must support the engine to normal position after removing the transaxle.



    D13C5021
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  5. Remove the pressure plate and the clutch disc.


  6. D13C5031
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  7. 4. Remove the transaxle input shaft bearing using the input shaft bearing remover 09917-58010, the flywheel holder 09924-17810 and a spanner.


D13C5041
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Inspection Procedure - Pressure Plate and Clutch Disc

  1. Pressure plate inspection .


  2. D103C505
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  3. Clutch disc inspection
  4. Unit : mm (in.)
    Rivet Head Depth
    Standard
    Limit
    1.2 (0.047)
    0.5 (0.02)


    D103C506
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  5. Clutch disc runout in rotational direction inspection.
  6. Unit : mm (in.)
    Disc Runout Limit in Rotational Direction (Periphery)
    0.7 (0.028)


D13C5071
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the input shaft bearing using the input shaft bearing installer 09925-98210 and the flywheel holder 09924-17810.


  3. D13C508B
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  4. Install the pressure plate and the clutch disc.
  5. Tighten
    Tighten the bolts to 18-28 N•m (13-21 lb-ft).



D103C509
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CLUTCH RELEASE BEARING, SHAFT AND BUSHING

Tools Required

09923-46040
Bushing Joint Pipe
09925-48220
Bushing Remover/Installer
09930-30102
Sliding Shaft
09943-88211
Bushing, Bearing Installer

Removal Procedure

  1. Remove the transaxle from the vehicle. Refer to Section 5B, Manual Transaxle.
  2. Remove the release arm. Refer to "Clutch Release Arm" in this section.


  3. D103C510
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  4. Remove the release bearing.
  5. Remove the release shaft and bushing.


  6. D103C511
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    D13C512A
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D103C513
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Inspection Procedure - Release Bearing and Shaft

  1. Release bearing inspection


  2. D103C514
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  3. Release shaft inspection


D103C515
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the release shaft bushing (No.1) using the bushing joint pipe 09923-46040, bushing, bearing installer 09943-88211 and a hammer.


  3. D103C516
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  4. Install the release shaft bushing (No.2) and seal using the bushing remover/installer 09925-48220 and a hammer.


  5. D103C517
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  6. Install the release bearing.


D103C518
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CLUTCH RELEASE ARM

Removal Procedure

  1. Disconnect the clutch cable.


  2. D103C519
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  3. Remove the clutch release arm.


D13C520A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the clutch release arm.
  3. Tighten
    Tighten the bolt and nut to 10-16 N·m (7.5-12 lb-ft).

  4. Adjust the clutch cable. Refer to "Diagnosis" in this section.


D103B506
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CLUTCH CABLE

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the clutch cable from the transaxle.


  2. D13C5211
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  3. Disconnect the clutch cable from the pedal.


  4. D103C522
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  5. Remove the battery. Refer to Section 1E, Engine Electrical.
  6. Remove the clutch cable.


D103C302
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Installation Procedure

  1. Install the clutch cable.
  2. Install the battery.
  3. Connect the clutch cable to the pedal.
  4. Connect the clutch cable to the transaxle.
  5. Adjust the clutch cable. Refer to "Diagnosis" in this section.


D103C524
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CLUTCH PEDAL

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the clutch cable. Refer to "Clutch Cable" in this section.
  2. Remove the clutch pedal.


D103C302
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Installation Procedure

  1. Install the pedal return spring.
  2. Install the bushings.
  3. Install the clutch pedal.
  4. Install the nut.
  5. Fix the pedal return spring.
  6. Connect the clutch cable.
  7. Adjust the clutch cable. Refer to "Diagnosis" in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Clutch Disc
Type
-
Single Dry Plate
-
Outside Diameter
mm (in.)
170 (6.7)
-
Inside Diameter
mm (in.)
110 (4.3)
-
Thickness
mm (in.)
7.15 (0.281)
-
Rivet Head Depth
mm (in.)
1.2 (0.047)
0.5 (0.020)
Disc Runout Limit in Rotational Direction
mm (in.)
-
0.7 (0.028)
Clutch Pedal
Pedal Free Travel
mm (in.)
0 (0)
-
Pedal Travel
mm (in.)
100 - 110 (3.9 - 4.3)
-
Clearance between pedal and floor just before clutch connection
mm (in.)
-
30 - 40 (1.2 - 1.6)

FASTENER TIGHTENING SPECIFICATIONS

Application
N·m
Lb-Ft
Lb-In
Pressure Plate Bolt
18 - 28
13 - 21
-
Clutch Release Arm Bolt and Nut
10 - 16
7.5 - 12
-

SPECIAL TOOLS

SPECIAL TOOLS TABLE


D103C101
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09917-58010 Input Shaft Bearing Remover

D103C105
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09923-46040 Bushing Joint Pipe

D102B116
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09924-17810 Fly Wheel Holder

D103C104
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09925-48220 Bushing Remover/Installer

D103C102
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09925-98210 Input Shaft Bearing Installer

D103C106
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09930-30102 Sliding Shaft

D103C107
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09943-88211 Bushing, Bearing Installer

D103B103
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DW110-021 Engine Assembly Support Fixture

D103C103
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DW210-010 Clutch Center Guide


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