Clutch Replacement

1. Separate transaxle from engine as described under Manual Transmission/Transaxle.
2. Remove boot from clutch housing, then squeeze set spring and release fork from clutch housing.
3. Remove and inspect release bearing for excessive play by hand spinning, then pack bearing with grease before installation. Do not wash bearing in solvent.
4. Inspect finger of diaphragm spring for wear.
5. Check diaphragm spring fingers height using clutch alignment disc tool No. 07JAF-PM7011A and clutch alignment shaft tool No. 07LAF-PT00110, or equivalents. Spring finger height should be 0.02-0.03 inches.
6. Install ring gear holder tool No. 07LAB-PV00100, or equivalent, then remove pressure plate mounting bolts by turning bolts two turns at a time in a crisscross pattern.
7. Remove pressure plate and clutch disc.
8. Inspect pressure plate surface for wear, cracks or burning.
9. Inspect pressure plate warpage. Service limit is 0.006 inches.
10. Inspect lining of clutch disc for signs of slipping or oil. Replace if burned or oil soaked.
11. Measure clutch disc thickness. Minimum thickness is 0.24 inches.
12. Measure depth from lining surface to rivets on both sides. Minimum depth is 0.008 inches.
13. Inspect ring gear teeth for wear and damage, then inspect flywheel clutch disc mating surface for wear, cracks and burning.
14. Measure flywheel runout by push against flywheel while turning to take up crankshaft thrust washer clearance. Runout must be less than 0.006 inches. If resurfacing requires removing more than 0.013 inch, replace flywheel.
15. Turn flywheel bearing inner race with finger and check for smooth quiet rotation, then check outer race to ensure tight fit.
16. Remove eight mounting bolts and flywheel, then the bearing.
17. Install new flywheel bearing with special tools No. 07749-0.01000 and 07746-0010100, or equivalents.
18. Align hole in flywheel with crankshaft dowel pin and install flywheel, then install bolts finger tight.
19. If flywheel was removed, install ring gear holder and torque flywheel bolts to 76 ft. lbs. in crisscross pattern.
20. Apply suitable high temperature grease to clutch disc spline and aligning flywheel dowels with pressure plate holes, then install clutch disc and pressure plate.
21. Insert clutch alignment shaft tool No. 07LAF-PT00110, or equivalent, into splined hole in clutch disc.
22. Tighten bolts two turns at a time in crisscross pattern to prevent warping diaphragm spring. Torque bolts to 19 ft. lbs.
23. Remove special tools.
24. Apply suitable high temperature grease to release bearing grooves, mainshaft splines and fork contract surfaces. Install release fork set spring. With fork slid between pawls, install release bearing on mainshaft while inserting fork through clutch housing hole. Align fork detent with bolt, then press fork over bolt. Torque bolt to 22 ft. lbs., then move fork right and left to ensure proper fit and bearing slides freely. Ensure boot seals around fork and housing.