Flywheel: Service and Repair

Clutch Replacement
Special Tools Required
^ Clutch alignment shaft 07ZAF-PR8A100
^ Clutch alignment disc 07JAF-PM7011A
^ Remover handle 07936-3710100
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Attachment, 22 x 24 mm 07746-0010800
^ Driver 07749-0010000

Pressure Plate and Clutch Disc Removal
1. Check the height of the diaphragm spring fingers using the special tools and a feeler gauge. If the height is more than the service limit, replace the pressure plate.





2. Install the special tools.





3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).
4. Inspect the surface of the pressure plate (A) for wear, cracks, and burning.





5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area.
6. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.





7. Remove the clutch disc and special tools.





8. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch looks burnt or is oil soaked, replace it. Find and repair the source of the oil leak if the clutch disc is soaked.
9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.





10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc.





Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended.





Flywheel Replacement
1. Install the special tool.





2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.
3. Install the flywheel on the crankshaft, and install the mounting bolts, finger-tight.
4. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.





Crankshaft Pilot Bushing Inspection
1. inspect the crankshaft pilot bushing for wear end damage.
2. Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it.





Crankshaft Pilot Bushing Replacement
1. Remove the crankshaft pilot bushing (A) using the commercially available tools (B).





2. Install the new crankshaft pilot bushing (A) into the crankshaft using the special tools. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing surface.





Clutch Disc and Pressure Plate Installation
1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
2. Install the ring gear holder.





3. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (A).
4. Apply super high temp urea grease (P/N 08798-9002) to the splines (B) of the clutch disc (C), then install the clutch disc using the special tools.
5. Install the pressure plate (A) and the mounting bolts (B), finger-tight.





6. Hand-tighten the mounting bolts in a crisscross pattern in several steps to prevent warping the diaphragm spring. Then torque the bolts to the specified torque.





7. Remove the special tools.
8. Make sure the diaphragm spring fingers are all the same height.

Release Bearing Replacement
1. Remove the release fork boot (A) from the clutch housing (B).





2. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).
3. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one.

NOTE: The release bearing is packed with grease. Do not wash it in solvent.





4. Apply super high temp urea grease (P/N 08798-9002) to the release fork A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.





5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.
6. Align the detent of the release fork with the release fork bolt, then squarely press the release fork over the release fork bolt.
7. Install the release fork boot (E), make sure the boot seals around the release fork and clutch housing.
8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly.