Clutch Assembly Replacement (MVE Manual Transmission)

Clutch Assembly Replacement (MVE Manual Transmission)

Removal Procedure




1. Remove the manual transaxle assembly. Refer to Transmission Replacement (Transmission Replacement).
2. Remove the clutch release fork with the clutch release bearing from the manual transaxle.




3. Remove the clutch release fork boot from the manual transaxle.




4. Remove the release bearing and clip from the clutch release fork.




5. Remove the release fork support (1) from the manual transaxle.




6. Put matchmarks (1) on the clutch cover assembly and the flywheel sub-assembly.
7. Loosen each bolt (2) one turn at a time until the spring tension is released.
8. Remove the bolts and pull off the clutch cover.
9. Remove the clutch disc assembly.




10. Using vernier calipers, measure the rivet head depth.

Minimum rivet depth: 0.3 mm (0.012 in)
If necessary, replace the clutch disc assembly.

Note: Insert the clutch disc assembly in the correct direction.

11. Install the clutch disc assembly onto the transaxle assembly.




12. Using a dial indicator (1), measure the clutch disc assembly runout.

Maximum runout: 0.8 mm (0.031 in).
If necessary, replace the clutch disc assembly.




13. Using vernier calipers, measure the depth (a) and width (b) of the diaphragm spring wear.
If necessary, replace the clutch cover assembly.




14. Using a dial indicator (1), measure the flywheel sub-assembly runout.

Maximum runout: 0.1 mm (0.004 in)
If necessary, replace the flywheel sub-assembly.




15. Check that the clutch release bearing assembly moves smoothly without abnormal resistance by turning the sliding parts of the clutch release bearing assembly-contact surfaces with the clutch cover-while applying force in the axial direction.
16. Inspect the clutch release bearing assembly for damage and wear.
If necessary, replace the release bearing assembly.





Installation Procedure





Note: Insert the clutch disc assembly in the correct direction.

1. Insert a clutch pilot tool (1) into the clutch disc assembly, then insert them both into the flywheel sub-assembly.




2. Align the matchmark (2) on the clutch cover assembly with the one on the flywheel sub-assembly.

Caution: Refer to Fastener Caution (Fastener Caution).

Note:
* Tighten the bolts evenly one turn at a time.
* Move the pilot tool (1) up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

3. Tighten the bolts in order, starting with the bolt located near the knock pin at the top to 19 Nm (14 lb ft).




4. Using a dial indicator with a roller instrument (1), check the diaphragm spring tip alignment.

Maximum non-alignment: 0.9 mm (0.035 in)

5. If the alignment is not as specified, adjust the diaphragm spring tip alignment.




6. Install the release fork support (1) onto the transaxle assembly and tighten to 37 Nm (27 lb ft).




7. Install the clutch release fork boot to the manual transaxle.




8. Apply grease to the contact surfaces of the release fork, release bearing assembly, release fork push rod, and release fork support.
9. Install the release fork onto the release bearing assembly with the clip.




10. Apply grease to the input shaft spline.
11. Install the clutch release bearing with the release fork onto the transaxle assembly.
12. Install the manual transaxle assembly. Refer to Transmission Replacement (Transmission Replacement).