Clutch Disc: Service and Repair

Clutch Assembly Replacement

Tools Required

* J 36547 Input Shaft Seal Installer
* J 42474 (KM-735) Clutch Arbor or equivalent

Removal Procedure





Caution: Refer to Battery Disconnect Caution Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
3. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation Service and Repair in Tires and Wheels.
4. Remove the transaxle from the vehicle. Refer to Transmission Replacement Removal and Replacement in Manual Transmission.
5. Remove the pressure plate bolts and the pressure plate. Support the pressure plate when removing the last bolt.




6. Remove the clutch disc.




7. Remove the release fork bolt.




8. Pull the clutch release shaft upward, out of the transaxle.




9. Remove the fork and the release bearing form the release bearing guide sleeve.




10. Remove the bolts and the release bearing guide sleeve.




11. Remove the input shaft seal from the release bearing guide sleeve.




12. Remove the O-ring from the groove in the transaxle case.




13. Remove the release lever shaft bushings.

Installation Procedure




1. Install the release lever shaft bushings. Coat the bushing bores with multi-purpose glass.




2. Install the O-ring into the groove in the case.




3. Install the input shaft seal into the release bearing guide sleeve. Use the J 36547 (1) with a hammer.





Notice: Refer to Fastener Notice Fastener Notice in Cautions and Notices.

4. Install the release bearing guide sleeve and the bolts.

Tighten the release bearing guide sleeve bolts to 5 Nm (44 lb in).

5. Coat the sleeve surface with multi-purpose grease.




6. Coat the release bearing bore with multi-purpose grease.
7. Install the release bearing, with the clutch fork, onto the release bearing guide sleeve.




8. Install the release lever shaft from the top of the transaxle. Guide the shaft through the clutch fork.




9. Align the shaft to the fork and install the bolt.

Tighten the clutch fork-to-release lever shaft bolt to 35 Nm (26 lb ft).




10. Coat the spline on the clutch disc with multi-purpose grease.
11. Align the pressure plate and the clutch disc onto the flywheel using the J 42474 (1).
12. Install the pressure plate bolts.

Tighten the pressure plate-to-flywheel bolts to 15 Nm (11 lb ft).

13. Remove the J 42474 (1).
14. Install the transaxle into the vehicle. Refer to Transmission Replacement Removal and Replacement in Manual Transaxle.
15. Install the left front wheel. Refer to Tire and Wheel Removal and Installation Service and Repair in Tires and Wheels.
16. Lower the vehicle.
17. Connect the negative battery cable.