CLUTCH 40.

GROUP40

CLUTCH
A mnxrnc
THECLUTCHDISCCONTAINSASBESTOS FIBERSWHICHCANBECOMEAIRBORNE IF DUSTIS
CREATEDDURINGSERVICING.
BREATHING DUSTCONTAININGASBESTOS
FIBERSMAYCAUSE
SERIOUSBODILYHARM.WHENSERVICING CLUTCHPARTS,DO NOTCREAT€DUSTBY GRINDING OR
SANDINGCLUTCHDISCOR BY CLEANINGPARTSWTH A DRYBRUSHOR WITHCOMPRESSED AIR.A
WATERDAMPENED CLOTH.NOT SOAKED.SHOULDBE USEDINSTEAD,
* Notice
Always reinstallfastenersat the same locationtrom whichthey werc removed.Use the correctpaft number
fastenerfor that applicationif a fastenerneeds to be rcplaced.A fastenerof equal size and strangth(or strongeo
may be used if the correctpaft numberfasteneris not available.Fastenersthat are not to be reusedor that
requirethreadlocking compoundwill be identified. Wheninstallingfastenersthat reguircprecisiontightening,
specifiedtighteningvalues mustbe used. Pafts or systemdamagecould result if the aboveconditiohsare iot
followed.

CONTENTS
Diagnosis. .. 40-3
GeneralDescription ...... 4O-1
On-VehicleService.. 4O-4
Bleeding.. 40-5
BrakeFluidLevel.... 4O-4
Clutchand FlywheelAssembl; . . 4O-8
ClutchCover(lnspection) 4O-9
ClutchCover(lnstallation) .. .. 40-11
ClutchCover(Removal) 4O-8
ClutchDisc(lnspection). 40-9
ClutchDisc(lnstallation) ..... 40-11
Flywheel (lnspection) ..... ... 40-.11
Flywheel (lnstallation). .. .. .. 40-11
Flywheel (RemovaD ....... 40-8
PilotBearing(lnstaation) .... 40-14
PilotBearing(Removal). 40-9
ReleaseBearing(lnspection) 40-.10
R e l e a sBee a r i nIgn s t a l l a t i o n ) .......... 40-11
fnspectionandAdjustment. 4O-4
ClutchPedalHeight. . 4O-4
PedalFreePlay..... 4O-4
ClutchMasterCylinder. . . 4O-5
PedalAssembly. 4O-4
ReleaseCylinder. 4O-7
Specifications 40-12
Fastener'l'ightening Specitications. 40-12
GENERALDESCRIPTION
The clutchis a singledry disctype,witha clutchcover
that usesa diaphragm spring.Theclutchis hydraulically
actuated;thereis a clutchmastercylindernearthe
clutchpedalanda releasecylindernearthe clutch
assembly.
CLUTCH
ASSEMBLY
4O-2 CLUTCH

1.1.Cilindro
Clutch MasterCylinder
maestro del embrague
2.2.Cilindro
Releasede Cylinder
liberación
Release
3.3.Soltar Fork
la horquilla
4.4.Cojinete
Felease deBearing
liberación
5.5.Cubierta
ClulchCover
de embrague
6.6.Disco
Clutch
de Disc
embrague
7.7.Volante
Flywheel
8.LRodamiento
Pilol B€aring piloto
9-9-Manguera flexible
FlexibleHose

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 CLUTCH 40.3

DIAGNOSIS
Problem PossibleCaus€ Action
Sllpping Clulch disc lacingexcessivelywom Replace
Clutchdisclacingsurfacehardened, or oil on surface Repairor replace
Cover damag€d Repairor replace
Diaphragm springdamagedor weakened Replace
cldch pedalplay
Insufficient Adjust
Pedalsticking Repairor replace
FlywhEeldamaged Repairor replace
Faulty disengagemenl Excessiverun-outor damagedclulch disc Replace
Clutchdiscsplinesrustedor wom Removerustor replace
Oil on discfacing Repairor replace
Weakdiaphragm Replace
Excessivecldch pedaltree play Adjus!
Insuflicient
brakefluid Addfluid
Leakingslavecylinder Repairor replac€
Lgakingmaste.cylindel Repairor replace
Leakinghydraulic line Replace
Vlbrates when starting Oalon disc tacing Replacedisc
Weaktorsionspring Replace
Clutchdisctacinghardened or damaged Repairor replace
Looseclulch disc rivets Replace
Cover damaged Replace
Excessivecoverrun-out Replace
Flywh€elsudacehardened or damaged Repairor replac€
Looseor brokenenginemount Repairor replace
Clutch pedal stiddng Pedalshalt not properlylubricated Lubricate
Excessively|'rompedalshatt Replace
Abnormal rpise Damagedreleasebearing Replace
Rel€asebearingsleevenot properlylubricaled Lubricate
Weaktorsionspring Replace
Excessivecrankshaftend play Repair
Wom or damagedpilot bearing Replace
Wom releasefork Divotooints Replace
4O.4 CLUTCH

ON.VEHICLE
SERVICE
BRAKEFLUIDLEVEL {'
1. Cleanthe areaaroundthe brakefluid reservoircao.
2. lf thefluidlevelis nearor belowthe MINmark,add
fluidto the MAXmark.
Brakefluid: DOT-3or DOT-4(FMVSS116or SAE
J1703a)

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9.84 in (250mm)
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PEDALASSEMBLY
INSPECTION AND ADJUSTMENT Removal
'1. Removeclipand pin.
Clutch PedalHeight
2. Removereturnspring.
Inspection
3. Removenut,washerandbolt.
Pullbackcarpetandmeasurethe distancefromthe
uppersurfaceof the pedalpadto the bulkhead. 4. Removespacerandtwo bushings.
Standardheight: 9.84in (250 mm) Installation
Adiustment 1. Installnewpedalpadif needed.
1. Adjustthe clutchpedalheightby loosening
the tock 2. Installnew stopperif needed.
nut(A)andturningstopperbolt(B). 3. Installtwo new bushings if needed.Applylithium
2. Afterthe adjustment, tightenlocknut. basegreaseto the bushingsand pivoi points.
Tighten nut to 12 lb.'ft (16 N.m). 4. Installnut, washerand bolt.
Tighten nut to 20 lb-ft (27 N.m).
ClutchPedalFreePlay
Installnew returnspringif needed.
Inspection 6. Installpushrodwithclipandpin.
Pushthe clutchpedallightlyby handand measurethe
free play. 7. Measureand adjustpedalfree play it needed.
Freeplay:0.5 in (12.7mm) Freeplay: 0.50in (12.7mm)
Tighten push rod adiustmentlocking nut to
Adjustment 20 lb-ft (27 N.m).
1. Adjustthe freeplayby loosening locknut(C)and
tuminglhe pushrod(D).
2. Checkthat the distancefromthe floorto the center
of the uppersurfaceof the pedalpad is correct
whenthe pedalis luuy extended.lf it is not within
specification,adjust.
3. Whencorrectlyadjusted,tightenlocknut.
Disengagement height:7.25in (184mm)
 CLUTCH 40.5

CLUTCHMASTERCYLINDER
Removal
* Notice
Toavoidpaint damage,paintedsurtaces
surroundingthe mastercylindershouldbe covered.
1. Usinga linewrench,disconnectsteelhydraulicline.
i'i:.
, 5 Thebrakehydnulic systemreseNoirprovidesbrake
il l l 4 fluid lor the clutchcontrol system.Topreventlossof
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brake fluidduringclutchmastercylindetremoval,the
A,
disconnectedhydraulicfluid tnnsfer hosemustbe
!
pluggedot direcledinto a suitable@ntainer.
2. Disconneclbrakefluidtransferhose.
12 7
3. Fromenginecompartment, removelowermounting
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Frompassengercompartment, r€moveuppernut

#4
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3 fromclutchmastercylindermountingstud.
I
9 d Removeclutchmastercvlinderandoasket.

1. Bolt
qrr, "/
2. Nd \
3. RetumSp.ing
4. Nut
5. PlainWasher (,
0-\
6. Bolt 16
7. Spacer
8. Busing
9. Clip
'lO. Pin
11. Nut
't2. PushRod l ClutchPipe
13. Cldch Fork 2 . ReseryoirTankHose
14. Slopper 3 . Nut
15. ClutchPedal 4 . ClutchMasterCylinder
16. PedalPad Gasket

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BLEEDING Disassembly
Thebrake fluidreseruoirmustbe more than3/4 full 1. Pressdownon the pistonand removethe stopwire
duing bleeding. with needle-nose
oliers.
All air mustbe bledout ot the hydraulicsystemfor
correctclutchoperation.
1. Removebleedercao.
2. Attacha suitablehoseto the bleederscrewand
directendof hoseintosee-through container.
3. Hold the clutchpedaldown,openthe slavecylinder
bleederscrewto let any air escape.Closebleeder
screwand let the pedalup.
4. Repeatstep 1 untilonlyfluidcomesout of the
bleederscrew.
5. Replacebleedercap and discardusedbrakelluid
in coniainer.
40.6 CLUTCH

With slop wire removed,use compressed

air to lnstallation
removethe pistonand secondarycup assembly,
primarycup and returnspring. 1. Usingnew gasket,placeassembledmastercylinder
on enginecompartment bulkhead. t :
J. Use brakefluidto cleaninnerparts.
2. Installnut on rylinderuppermountingstudfrom
passengercompartment.
3. Installnut on lowercylindermountingboltfrom
enginecompartment.
Tighrenboth nuts to 17 lb-ft (23 N.m).

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Inspection
Aftercleaning,inspectand replacethe followingpartsif
necessary:
1. Wornor damagedclutchmastercylinderboreand X|Ar€3{OOrS
piston.
2. Weakreturnspring.
3. Wom or damagedprimaryor secondarycups.
4. Installsteelhydraulicline.
Assembly Tightento 13 ltstt (17 N.m).
1. Coatthe pistonandcups with cleanbrakefluid.
5. Connectbrakefluid transterhose.
2. Insertretumspring,primarycup, pistonand
secondarycup assembly,and pistonstopwasher 6. Fill brakefluid reservoirto recommended
level.
intocylinderbore.
3. Installstop wire usingneedle-nosepliers.
4. Snapin bushingand reservoirtankhose.
5. Fill cylinderwithnewbrakefluid and operatethe
pistonuntilfluidcomesout ot ouflet.

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1. StopWire
PistonSlop Washer
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Pislon& SecondaryCup
N--- Assembly
4. PrimaryCup
5. RetumSpring
ReservoirTankHose
7. Bushing
ClutchMasterCylinder
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 CLUTCH 4O.7

RELEASECYLINDER

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'1. FlexibleHose
2. Boot
3. PushRod
4. Pistonand CapAssembly
5. FletumSpring
6. BleederCap
1. 7. BleederScrew
2. ClutchPipe 8. SteelBall
3. ReleaseCylinder 9. ReleaseCylinder
FlexibleHose (|^ier+r3S

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Removal
Toprevent lossof brakefluid duing clutchslavecylinder
removal,the disconnectedsteelhydraulicline mustbe
pluggedor directedinto a suitablecontainer.
1. Disconnectflexiblehosefromsteelhydraulicline.
* Notice
Twistingmay damagethe flex hose.
2. Removehydraulicline retainerclip.
3. Removetwo bolts.
Inspection
Aftercleaning,inspectthe followingparts:
1. Releasecylinderboreand pistonfor wear.
2. Weakretumspring.
Assembly
1. Coatthe pistonand cupswith cleanbraketluid.
2. Insertsteelballin cylinderbleederholeand secure
with bleederscrew.
3. Pushbleedercap overbleederscrewend.
4. Insertretumspringand pistonand cupassembly
intocylinderbore.
5. Withbootinstalledon push rod,insertrod into
cylinderboreand snapboot in place.
6. Connectflexiblehoseto the cylinderbody.
Tightenflexible hose nut to 16 lb-tt (22 N.m).
lnstallation
1. Withcylinderpushrod in clutcharmdetent,attach
cylinderto the transmission casewithtwo bolts.
Tighlen bolts to 17 lb-tt (23 N.m).
2. Installflexiblehoseontohydraulicline.
Tighten bolts to 17 lb-ft (23 N.m).

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Disassembly
1. Removeflexiblehose,boot,and pushrod.
2. Removepistonand cap assemblyand return
spnng.
3. Removebleedercap, bleederscrew,and steelball.
4. Usebrakefluidto cleaninnerDarts. (tAr5+Ora-s
40€ CLUTCH
3. MountflexiblehoseontorelainerstraDand install 1. Installclutchdisccent€ringtool and ringgear
cliP. brake.
* Notice Removesix clutchcovermountingbolts.
Twistingmay damagethe flex hose. Removeclutchcoverand clutchdiscfromflvwheel.
4. Fill brakelluid reservoirto recommended
level.
5. Performbleedingprocedure,see bleedingin this ClutchDisc
section. CenteringTool

Ringcear
Brake

HexagonNut

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Flywheel
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Required:
. Bing GearBrake
CLUTCHAND FLYWHEEL
ASSEMBLY * t'totice
Flwheel is heavy and if not suppoftedwill fa from
vehiclewhenall the mounting boltsare removed.
1. Withringgearbrakein place,removeeightflywheel
bolts.
2. Removeflywheeltromcrankshaft flange.

Flywheel
Pilot Bearing

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ClutchCover
Removal
Reouired: |(|Ar69:F.ta€
. ClutchDiscCenteringTool
. RingGear Brake
,F uotice
Clutchcover is heavyand if not suppoftedit will falt
frcm vehicle whenall the mounting boll.sare
removecl.
 CLUTCH 4O-9

Pilot Bearing Replaceif tacingrivetsar€ looseor missing.

Removal Replacewom disc.Measurerivetheaddepthwith
a slidecalioer.
Reouired:
inimumdepth:0.012in (0.3mm)
. BearingPuller
lf replacement
is required,removebearingusinga
bearingpuller.
030mm
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4 . Checkrunoutof disc.
Maximum:0.027in (0.7mm)
ClutchCover Replaceif splineis worn or heavilyrusted.Minor
rust may be removedwith steelwool.
Inspection
1. Insoectclutchcovercontactsurfaceof the clutch
discfor scoring,cracks,or discoloration.
Minor
scoringor discoloration
shouldbe removedwith
emerypaper.
2. Inspectdamageto coveror diaphragmspring.

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ClutchDisc
!nspection
1. Replaceil flywheelcontactfacingis hardened.
* Notice
An oil-contaminateddiscshouldalwavsbe
reDlaced.
40-10 cLuTcH

ReleaseBearing 2. Examinefor damagedor worn ring gearteeth.lf

necessaryreplaceringgear as follows:
Inspection a. Grindalmostthroughring gear,thencutthrough ( .
2* Notice remainingmaterialwith chisel.
Do not clean releasebearingwith solvent.Solvent b. Heatthe new ringgearto 480-570"F
will remove sealed-inlubricantand will cause (250-300'C),thentit onto the roomtemperature
bearingfailure. flywheel.The beveledside of the ringgearmust
1. Rotatethe bearingin bothdirectionsand checkfor tacetowardthe engineside of flywheel.
anybindingor abnormal noise.
2. Replaceif diaphragmspringor releasefork contact
surtacesare wom or damaged.
3. Installthe bearingon the transmission inputshaft
andchecktor smoothmovement.

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* Notice
Make sure thereis no dift or debis between
flwheel and crankshaftflange whenpeiorming the
runout check.
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3. Inspectfor runoutas follows:
a. Withflywheelattachedto engine,mountdial
indicatorwithgaugeplungertouchingflywheel
Flywheel clutchcontactsurface.Tum engineby handand
recordmaximumreading
Inspection Runout maximum:0.008in (0.2 mm)
1. Examinelor cracks,scoringor discoloration
ot the b. lf the runoutexceedsspecification,
repairby
clutchcontactsurface.Minorsurfacemarringcan resurfacing(grinding).
be repairedwith emerypaper.OtheMise,flywheel
mustbe machineresurfaced or replaced. Maximumresurfacingdepth: 0.020in
(0.5 mm)

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 CLUTCH 40-11

Flywheel Clutch Cover

Installation Installation
Required: 1. Withclutchdischeldin placeby centeringtoot,
. RingGearBrake mountclutchcoveroverlool and installsix bolts.
1. Placeflywheelover end of exposedengine Tighten bolts lo 16 lb-ft (22 N.m).
crankshaft. 2. Removeclutchdisccenteringtool and ringgear
2. Insertand handtighteneightbolts. braketool.
Tightenbolts to 73 lb-tt (99 N.m)
Pilot Bearing
Insta!lation
Coatb€aringwithlithiumbasegreaseandtheninstall
usingbearinginstallation
tool.

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ReleaseBearing
Installation
|(|At6g.aqts greaseto the shadedareas.
Applyorganicmolybdenum
ClutchDisc
Installation
Flequired:
. ClutchDiscCenteringTool
1. Aftercleaningthe clutchdiscand primaryshaft
splines,applyorganicmolybdenum grease.
2. Holdclutchdisc in placewithclutchdisc centering
tool.

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40-12 CLUTCH

SPECIFICATIONS l - .
FASTENER
TIGHTENING
SPECIFICATIONS
Clutch CoverBolts.... . ....16lb-tt(22N.m)
ClutchPedalLockNut. .....12 tb-fr(16N.m)
Cyfinder-to-Transmission CaseBolts.... ......171b-ft(23N.m)
Flexible HoseNut..... ..16lb-ft(22N.m)
Ffexibfe Hose-to-Hydraulic LineBolts.. . . .. .. ...17lb-tt (23N.m)
Flywheel-to-Crankshaft Bolts ........73 |b-ft(99N.m)
LowerCylinderMountingNut.. .. . . .. . 17lb-tt(23N.m)
PedalAssemblyNut. . . . . .20 tb-fr(27N.m)
PushRodAdiustmentLockingNut .. .. . . . . . .20 lb-tt(27N.m)
SteelHydraulic Line..... ..13 tb-ft(17N.m)
U p p eCr y l i n d eMr o u n t i nSgt u dN u t . . . . . . . . . . . . . 1 7 l b - f t( 2 3N . m )

Engine
FE DOHC
Item
ClutchControl Hydraulic
Type DiaphragmSpring
ClutchCover
Set Load lb. l, too

OuterDiameter in (mm) 8.86(22s)

ClutchDisc InnerDiameter in (mm) 5.91(1s0)
Thickness in (mm) 0.138(3.5)
Type Suspended
PedalRatio in (mm) 6.9:1
ClutchPedal
FullSlroke
in (mm) 6.1(155)
Height(withcarpet) in (mm) s.84(250)
ClutchMasterCylinderInnerDiameter in (mm) 0.625(1s.87)
ReleaseCylinderInnerDiameter in (mm) 0.750(19.05)
ClutchFluid SAEJl703 or FMVSS116DOT-3or 4