Clutch Disc: Service and Repair

Clutch Disc and Pressure Plate





Special Tool(s)

Removal

WARNING: Clutches and brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer. Failure to follow these instructions may result in personal injury. Breathing asbestos dust is hazardous to your health. Failure to follow these instructions may result in personal injury.

Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing. Failure to follow these instructions may result in personal injury.

Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600. Dust and dirt from vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.

If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. Grinding or sanding on brake linings, pads, rotors, drums or clutch facings should be done only while using correctly exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch service should be present in the area. Failure to follow these instructions may result in personal injury.

1. Remove the transaxle





2. Using the special tool lock the flywheel to the engine





3. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.

CAUTION: Loosen bolts evenly to prevent pressure plate damage.

Remove the bolts, clutch pressure plate, and clutch disc

4. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.

Using a suitable commercial alcohol base solvent, clean the clutch pressure plate
5. Inspect the clutch pressure plate surface for burn marks, scores flatness or ridges





6. Inspect the clutch pressure plate diaphragm fingers for wear. Install a new clutch pressure plate as necessary





7. Measure the depth to the rivet heads. Install a new clutch disc if any rivet head measurement is not within specifications.

8. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation.

NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface. Install a new clutch disc if any of the following conditions are present.

Inspect the clutch disc for:
^ oil or grease saturation
^ worn or loose facings
^ warpage or loose rivets at the hub
^ loose or broken torsion dampening springs
^ wear or rust on splines





9. Using the special tool, check clutch disc runout. Install a new clutch disc if not within specifications.

10. NOTE: Install a new clutch release fork if any of the following conditions are present.

Inspect the clutch release fork for:
^ cracks
^ distortion
^ excessive wear on the release bearing contact surface

Installation





1. Using the special tool, position the clutch disc on the flywheel.





2. Position the clutch pressure plate on the flywheel, install the pressure plate bolts and tighten them in sequence to specification.





3. Remove the special tool.





4. Remove the special tool.
5. Install the transaxle.