Clutch Disc: Service and Repair

Clutch Replacement

Special Tools Required
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Clutch alignment shaft 07LAF-PT00110
^ Attachment, 32 x 37 mm 07746-0010200
^ Driver 07749-0010000
^ Remover handle 07936-3710100

Pressure Plate Removal and Inspection
1. Transmission removal.
2. Check the height-variation of the diaphragm spring fingers using the dial indicator (A). If the variation is more than the service limit, replace the pressure plate.





3. Install the ring gear holder (A), clutch alignment shaft (B), and remover handle (C).





4. To prevent warping, remove the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
5. Remove the release bearing (F) from the pressure plate.
6. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.





7. Inspect the surface of the pressure (B) plate for wear, cracks, and burning.
8. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.





Release Bearing Inspection
9. Check the play of the release bearing by spinning it with your hand, if there is excessive play or noise, replace the release bearing.





Clutch Disc Removal and Inspection
10. Remove the clutch disc (A), clutch alignment shaft (B), and remover handle (C).





11. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is soaked with, oil replace it. If the clutch disc is oil soaked, find and repair the source of the oil leak.
12. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.





13. 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 and Pilot Bearing Inspection
14. Remove the ring gear holder.
15. Inspect the ring gear teeth for wear and damage.
16. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
17. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with pushing 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, go to step 19.





18. Turn the inner race of the pilot bearing (A) with your finger. The pilot bearing should turn smoothly and quietly. Make sure the pilot bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the pilot bearing, go to step 19.





Flywheel and Pilot Bearing Replacement
19. Install the ring gear holder (A).





20. Remove the flywheel mounting bolts (B) in a crisscross pattern in several steps, then remove the flywheel and ring gear holder.
21. Remove the pilot bearing (A) from the flywheel (B).





22. Install the new pilot bearing into the flywheel using the 32 x 37 mm attachment (A) and driver (B) as shown. Apply a light coat of engine oil to the bearing surface.





23. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts, finger-tight.
24. Install the ring gear holder (A), then torque the flywheel mounting bolts in a crisscross pattern in several steps.





Clutch Disc and Pressure Plate Installation
25. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Temporary install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft, and remove extra overflow grease.





26. Install the ring gear holder (C).
27. Install the clutch disc using the clutch alignment shaft (D) and remover handle (E).
28. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B), then install the release bearing on the pressure plate (C).





29. Install the pressure plate and the mounting bolts (D), finger-tight. Make sure the release bearing does not come off.
30. Torque the mounting bolts in a crisscross pattern in several steps to prevent warping the diaphragm spring.





31. Remove the ring gear holder, clutch alignment shaft, and remover handle.
32. Make sure the diaphragm spring fingers are all the same height.
33. Transmission installation.