Clutch Assembly Service

Inspection and Adjustment

CLUTCH DISC
Check the following items, and replace if necessary.





^ Clutch disc, for bums, discoloration, oil, or grease leakage
^ Clutch disc, for wear of facing
Wear limit of facing surface to rivet head: 0.3 mm (0.012 inch)





^ Clutch disc, for backlash of spline and runout of facing
Maximum backlash of spline (at outer edge of disc): 1.0 mm (0.039 inch)
Runout limit: 1.0 mm (0.039 inch)
Distance of runout check point (from hub center):
Model 240: 115 mm (4.53 inch)
Model 250: 120 mm (4.72 inch)

CLUTCH COVER AND FLYWHEEL





^ Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height.
Uneven limit:
KA24DE: 0.7 mm (0.028 inch)
VG33E: 0.5 mm (0.0020 inch)
^ If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.





^ Inspect contact surface of flywheel for slight bums or discoloration. Clean flywheel with emery paper.
^ Check flywheel runout.
Maximum allowable runout: Refer to Flywheel, M/T; Specifications or Flex Plate; Specifications.

Installation





^ Apply recommended grease to contact surface of splines.
^ Too much lubricant may damage clutch disc facing.
^ Insert Tool into clutch disc hub when installing clutch cover and disc.
^ Be careful not to allow grease to contaminate clutch facing.
^ Tighten bolts in numerical order, in two steps.
First step: 10 - 20 Nm (1.0 - 2.0 kg-m, 7 - 14 ft. lbs.)
Final step: 22 - 29 Nm (2.2 - 3.0 kg-m, 16 - 22 ft. lbs.)