Clutch: Service and Repair

REMOVAL AND INSTALLATION Manual Transmission/Transaxle





<2.0L Engine (Non-turbo)>

NOTE: The modular clutch assembly (Clutch & flywheel assembly) used in this vehicle consists of a single, dry-type clutch disc and a diaphragm style clutch cover. The clutch unit is serviced as an assembly. No disassembly is possible.





<2.0L Engine (Turbo) and 2.4L Engine>

REMOVAL SERVICE POINT
RELEASE FORK REMOVAL

Slide release fork in direction of arrow and disengage fulcrum from clip to remove release fork. Be careful not to cause damage to clip by pushing release fork in the direction other than that of arrow and removing it with force.

INSTALLATION SERVICE POINTS
>A< GREASE APPLICATION TO RELEASE FORK

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

>B< GREASE APPLICATION TO CLUTCH RELEASE BEARING





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

>C< CLUTCH DISC/CLUTCH COVER ASSEMBLY INSTALLATION





1. Apply specified grease to clutch disc splines and squeeze it in place with a brush.
Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent
2. Using clutch disc guide to position clutch disc on flywheel.

>D< GREASE APPLICATION TO CLUTCH RELEASE LEVER





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

>E< CLUTCH & FLYWHEEL ASSEMBLY INSTALLATION
1. Apply specified grease to clutch disc splines and squeeze it in place with a brush.
Specified grease: MITSUBISHI genuine grease Part No. 0101011 or equivalent

INSPECTION
<2.0L Engine (Turbo) and 2.4L Engine>
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 (0.020 inch)
- Check the pressure plate surface for wear, cracks and seizure.
- 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 inch)
- 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 play in the rotating direction. If it does not slide smoothly or the play is excessive, check after cleaning and reassembling. If the play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

CAUTION: Release bearing is packed with grease. Therefore do not wash it in cleaning solvent or the like.

- Check bearing for seizure, damage, noise, or improper rotation. Check also diaphragm spring contact surface for wear.
- Replace bearing if its release fork contact surface is abnormally worn.

RELEASE FORK
- Replace release fork if its bearing contact surface is abnormally worn.

<2.0L Engine (Non-turbo)>

CLUTCH & FLYWHEEL ASSEMBLY
- Check clutch assembly for contamination (dirt, oil). Replace clutch assembly, if required.
- Check to see if the clutch disc hub splines are damaged. Replace with new clutch assembly, if necessary.
- Check for uneven wear on clutch fingers.
- Check for broken clutch cover diaphragm spring fingers. Replace with new clutch assembly, if necessary.

CLUTCH RELEASE BEARING
- Check to see if the release bearing is sticky or binding. Replace bearing, if needed.

CLUTCH RELEASE LEVER/CLUTCH CONTROL EQUIP STUD
- Check linkage for excessive wear on the pivot stud and fork fingers. Replace all worn parts.