Repair Procedures

Removal

1. Remove the transaxle assembly.
2. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from shifting.




3. Loosen the bolts(6ea) which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover.

NOTE:
Do not clean the clutch disc or the release bearing with cleaning solvent.

When reusing a removed clutch
Find the position of the stop (A):
- There is only one.
- It is located on the pitch circle of cover assembly bolts between the bolt mount and the dowel pin, wedged between the cover assembly and the flywheel.
- The head of the guide bolt sticks out about 3 mm from the housing.




- Loosen the cover assy bolts opposite each other in increments (in approx. 5 stages), and
- Check that the stop (B) loosens and slides down to the block in the housing.
- The stop (B) must loosen when unscrewed from the housing (about 2mm).
- If necessary, push the guide bolt b (A)toward the flywheel.
- Loosen the cover assy bolts and remove the clutch from the flywheel.
- Place the cover assy on a clean surface.
- Do not clean the clutch disc or the release bearing with cleaning solvent.






Inspection

Clutch cover assembly
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

Clutch disc
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the thickness of the disc when free.

Standard value
Clutch disc thickness(A)[when free] :
[GSL 2.4] 8.7 ± 0.3 mm (0.343 ± 0.012 in)
[DSL 2.2] 8.8 ± 0.2 mm (0.346 ± 0.008 in)
Clutch disc rivet depth(B) : 1.3mm (0.051in)




3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

Installation

1. Apply multipurpose grease to the spline of the disc.

Grease: CASMOLY L 9508

CAUTION:
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease.
It can cause clutch slippage and vibration (shudder).




2. Temporarily install the clutch disc assembly to the flywheel using the special tool (09411-25000).




3. Tighten the bolts one or two steps at a time in a star pattern.

Tightening torque :
24.5 - 35.3N.m (2.5 - 3.6kgf.m, 18.1 - 26.0lb-ft)