Pressure Plate: Service and Repair

Clutch Disc and Pressure Plate

Special Tool(s):

Material:

Removal
1. Remove the transaxle.
2. Inspect the clutch pressure plate.
^ Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments.
^ Using the special tool, rotate the flywheel and check for spring ends that are higher or lower than the rest.
- The specification is 0.6 mm (0.02 in) maximum.





3. Using the special tool, lock the flywheel to the engine.





4. NOTE: Loosen each bolt, one turn at a time in a star pattern, until spring tension is released.

Using a suitable clutch disc aligner, remove the bolts, the clutch pressure plate and the clutch disc.





5. NOTE: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.

Using a suitable commercial alcohol-based solvent, clean the clutch pressure plate.
6. Inspect the clutch pressure plate surface for burn marks, scores, flatness, ridges or cracks.
^ Maximum clearance for flatness check is 0.3 mm (0.012 in).

7. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal or transmission input shaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation.

NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface.

Inspect the clutch disc for the following:
^ Oil or grease saturation
^ Worn or loose facings
^ Warpage or loose rivets at the hub
^ Wear or rust on the splines
^ Install a new clutch disc if any of the these conditions are present.

8. Check the clutch disc runout.
9. If necessary, conduct a flywheel runout check.
10. Remove the clutch release bearing.





11. Inspect the clutch release bearing for wear or damage.
^ Rotate the bearing while applying pressure in the axial direction. If the bearing feels rough, sticks or has excessive resistance, install a new bearing.





12. Inspect the release bearing guide tube for wear or damage.
^ Slide the release bearing on the guide tube. Check for roughness or sticking.

13. Remove the clutch release fork. Inspect the fork for wear or damage.

Installation
1. Apply a very small amount of grease in the clutch disc hub. Wipe off excess grease to avoid contaminating the clutch disc and affecting clutch function.
2. Using a suitable clutch disc aligner, position the clutch disc on the flywheel.





3. Position the clutch pressure plate on the flywheel and to the dowels. Install the 6 clutch pressure plate bolts.
^ Tighten the bolts one turn at a time in a star pattern. Tighten to 29 Nm (21 lb-ft).





4. Apply a small amount of grease to:
^ the clutch release fork fingers.
^ the clutch release fork spring.
^ the guide tube.
^ the clutch slave cylinder end that contacts the release fork.

5. Install the clutch release bearing and the clutch release fork.

6. NOTE: Apply a very small amount of grease to the transmission input shaft end and on the splines.

Install the transaxle.