Clutch Disc: Service and Repair

CLUTCH COVER AND DISC REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation. Refer to Removal and Installation of the Transaxle Assembly.

Removal steps
1. Clutch cover assembly
2. Clutch disc
3. Return clip
4. Clutch release bearing
5. Release fork
6. Fulcrum
7. Release fork boot








SERVICE POINTS OF REMOVAL
1. REMOVAL OF CLUTCH COVER ASSEMBLY / 2. CLUTCH DISC
Diagonally loosen bolts which attach clutch cover to flywheel. Back off bolts in succession, one or two turns at a time, to avoid bending cover flange.

Caution: DO NOT clean clutch disc or release bearing with cleaning solvent.

INSPECTION

CLUTCH COVER ASSEMBLY
- Check the diaphragm spring end for wear and uneven height.

Replace if wear is evident or height difference exceeds the limit.

Limit : 0.5 mm (0.02 in.)

- Check the pressure plate surface for wear, cracks and color change.

- Check the strap plate rivets for looseness and replace the clutch cover assembly if loose.





CLUTCH DISC
- Check the facing for loose rivets, uneven contact. deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective.

- Measure the rivet sink and replace the clutch disc if it is out of specification.

Limit 0.3 mm (0.012 in.)

- Check for torsion spring play and damage and if defective, replace the clutch disc.

- Combine the clutch disc with the input shaft and check sliding condition and check for play in the rotating direction. If it does not slide smoothly, check after cleaning and reassembling. If the play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

Caution: The release bearing is packed with grease, so don't use cleaning oil, etc. to clean it.

- Check for bearing heat damage, other damage, abnormal noise and/or improper rotation. Also check whether or not there is wear at the point of contact with the diaphragm spring.

- If there is abnormal wear at the point of contact with the release fork, replace the bearing.

RELEASE FORK
- If there is abnormal wear at the point of contact with the bearing. replace the release fork.





SERVICE POINTS OF INSTALLATION
5. APPLICATION OF GREASE TO RELEASE FORK

(1) Apply a coating of the specified grease to the point of contact with the fulcrum and the point of contact with the release bearing.

Specified grease: MITSUBISHI genuine grease Part No.0101011 or equivalent.

Caution: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; excessive grease will cause clutch slippage and shudder.

(2) Apply a coating of the specified grease to the end of the release cylinder's push rod and to the push rod hole in the release fork.

Specified grease: MITSUBISHI genuine grease Part No.0101011 or equivalent.





4. INSTALLATION OF CLUTCH RELEASE BEARING

Caution: For the release bearing of a resin sleeve, grease must not be applied to the sleeve part.

2. APPLICATION OF GREASE TO CLUTCH DISC / 1. CLUTCH COVER ASSEMBLY

(1) Apply a coating of the specified grease to the clutch disc spline, and then use a brush to rub it in.

Specified grease: MITSUBISHI genuine grease Part No.0101011 or equivalent.

(2) Using the clutch disc center guide position the clutch disc to the flywheel.

(3) Install the clutch cover assembly. Tighten the bolts a little at a time, working in a diagonal sequence, finally tightening them to the specified torque.