Clutch: Service and Repair
Clutch Disc and CoverREMOVAL
NOTE: The illustration below is for a Turbo model. However, perform the same procedures for the Non-turbo model.
1. Remove the transmission assembly from vehicle body.
2. Insert the ST on the flywheel.
ST 499747100 CLUTCH DISC GUIDE
3. Remove the clutch cover and clutch disc.
NOTE:
^ Take care not to allow oil to touch the clutch disc face.
^ Do not disassemble the clutch cover or clutch disc.
^ Be sure to label alignment marks on the flywheel and clutch cover before removing the clutch cover.
INSTALLATION
NOTE: The illustration below is for a Turbo model. However, perform the same procedures for the Non-turbo model.
1. Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing.
NOTE: When installing the clutch disc, be careful to attach in the correct direction.
ST 499747100 CLUTCH DISC GUIDE
2. Install the clutch cover to the flywheel and tighten the bolts to the specified torque.
NOTE:
^ When installing the clutch cover to the flywheel, position the clutch cover in order to make the gap between imbalance marks (40 paint mark) of flywheel and clutch cover 120° or more. (The imbalance marks show the residual imbalance direction.) - Note the front and rear of the clutch disc when installing.
^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order.
Tightening torque: 16 Nm (1.6 kgf-m, 11.8 ft. lbs.)
3. Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4. Install the transmission assembly.
INSPECTION
NOTE: The illustration below is for a Non-turbo model. However, perform the same procedures for the Turbo model.
1. CLUTCH DISC
1. Facing wear: Measure the depth from the facing surface to the rivet head. Replace if the face is worn locally or worn down to less than the specified value.
Depth to rivet head: Limit of sinking 0.3 mm (0.012 inch)
NOTE: Do not wash the clutch disc with any type of cleaning fluid.
2. Hardened facing Replace the clutch disc.
3. Oil soakage on facing Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other locations for oil leakage.
4. Deflection on facing: If deflection exceeds the specified value at the outer circumference of the facing, replace the clutch disc. ST 499747100 CLUTCH DISC GUIDE
Limit for deflection:
Turbo model 1.0 mm (0.039 inch) at R = 110 mm (4.33 inch)
Non-turbo model 0.7 mm (0.027 inch) at R = 110 mm (4.33 inch)
5. If there is spline wear, loose rivets, failed damper springs, etc., replace the clutch disc.
2. CLUTCH COVER
NOTE: Visually check the following items without disassembling, and replace or repair if defective.
1. Loose thrust rivet
2. Damaged or worn bearing contact area at the center of diaphragm spring
3. Damaged or worn disc contact surface of the pressure plate
4. Loose strap plate installation area
5. Worn diaphragm sliding area
