CLUTCH

C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
PRECAUTIONS .......................................................... 2 REMOVAL ........................................................... 10 F
Caution ..................................................................... 2 INSTALLATION ................................................... 10
PREPARATION ........................................................... 3 Disassembly and Assembly .................................... 10
Special Service Tools ............................................... 3 DISASSEMBLY ................................................... 10 G
Commercial Service Tools ........................................ 3 INSPECTION AFTER DISASSEMBLY ................ 10
NOISE, VIBRATION AND HARSHNESS (NVH) ASSEMBLY ......................................................... 10
TROUBLESHOOTING ................................................ 4 CLUTCH PIPING ....................................................... 11
H
NVH Troubleshooting Chart ..................................... 4 Removal and Installation ........................................ 11
CLUTCH ................................................................ 4 CLUTCH RELEASE MECHANISM ........................... 12
CLUTCH PEDAL ........................................................ 5 Removal and Installation ........................................ 12
On-Vehicle Inspection and Adjustment .................... 5 REMOVAL ........................................................... 12 I
Removal and Installation .......................................... 6 INSPECTION AFTER REMOVAL ....................... 12
INSPECTION AFTER REMOVAL ......................... 6 INSTALLATION ................................................... 12
CLUTCH FLUID .......................................................... 7 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 14 J
Air Bleeding Procedure ............................................ 7 Removal and Installation ........................................ 14
CLUTCH MASTER CYLINDER .................................. 8 REMOVAL ........................................................... 14
Removal and Installation .......................................... 8 INSPECTION AND ADJUSTMENT AFTER
K
REMOVAL ............................................................. 8 REMOVAL ........................................................... 15
INSTALLATION ..................................................... 9 INSTALLATION ................................................... 16
Disassembly and Assembly ..................................... 9 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 17
DISASSEMBLY ..................................................... 9 Clutch Control System ............................................ 17 L
INSPECTION AFTER DISASSEMBLY ................. 9 Clutch Master Cylinder ........................................... 17
ASSEMBLY ........................................................... 9 Clutch Operating Cylinder ...................................... 17
OPERATING CYLINDER .......................................... 10 Clutch Disc ............................................................. 17 M
Removal and Installation ........................................ 10 Clutch Cover ........................................................... 17

CL-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ECS004JW

● Recommended clutch fluid is brake fluid “DOT 3” or “DOT 4”. Refer to MA-17, "Fluids and Lubri-
cants".
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● When removing and installing clutch piping, use Tool.
Tool number : GG94310000 or Commercial equivalent
● Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
● Never use mineral oils such as gasoline or kerosene. It will
corrode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.
PCIB0272E

CL-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS008B7

Tool number
Description
Tool name B
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover
CL

D
ZZA0508D

KV30101600 Installing clutch cover and clutch disc

Clutch aligning bar (QR engine model) E
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in) dia.
F

S-NT405

ST20630000 Installing clutch cover and clutch disc

G
Clutch aligning bar (YD engine model)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.077 in) H

S-NT405

I
Commercial Service Tools ECS00CRA

Tool name Description

J
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin

L
ZZA0515D

GG94310000 Removing and installing clutch piping

Flare nut torque wrench M
a: 10 mm (0.39 in)

S-NT406

CL-3
 Symptom
CLUTCH

Reference page

Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)

Clutch does not disengage

NVH Troubleshooting Chart

CLUTCH PEDAL (Inspection and adjustment) CL-5

1
1
CLUTCH LINE (Air in line) CL-7

2
1
tion. If necessary, repair or replace these parts.

MASTER CYLINDER PISTON CUP (Damaged) CL-8

3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-10

4
2
ENGINE MOUNTING (Loose) EM-78 (QR engine model), EM-208 (YD engine model)

CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-12

1
CLUTCH DISC (Out of true) CL-14

5
CLUTCH DISC (Runout is excessive) CL-14

5
2
CLUTCH DISC (Lining broken) CL-14

5
CLUTCH DISC (Dirty or burned) CL-14

5
CLUTCH DISC (Oily) CL-14

5
2
2
CLUTCH DISC (Worn out) CL-14

2
2
CLUTCH DISC (Hardened) CL-14

2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

CLUTCH DISC (Lack of spline grease) CL-14

5
DIAPHRAGM SPRING (Damaged) CL-14

6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-14

6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion) CL-14

7
4
FLYWHEEL (Distortion) EM-108(QR engine model),EM-235 (YD engine model)

5
PFP:00003

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ECS008B8
 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

A
On-Vehicle Inspection and Adjustment ECS001WB

1. Check to see if clevis pin floats freely in bore of clutch pedal. It

should not be bound by clevis or clutch pedal. B
a. If clevis pin is not free, check that pedal stopper bolt is not apply-
ing pressure to clutch pedal causing clevis pin to bind. To adjust,
loosen lock nut and turn pedal stopper bolt.
CL
b. Tighten lock not.
c. Verify that clevis pin floats in bore of clutch pedal. It should not
be bound by clutch pedal. D
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
clevis pin removed for step 2.
E
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move clutch pedal up and
down to determine if it moves freely.
F
b. If any sticking is noted, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
and re-verifity that clevis pin floats freely in bore of clutch pedal.
G

H
PCIB0814E

3. Check clutch hydraulic and system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever, clutch release bearing, etc.) for sticking or binding. I
a. If any sticking or binding noted, repair or replace related parts as necessary.
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-7, "Air Bleeding
Procedure" . J
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system. K

CL-5
 CLUTCH PEDAL

Removal and Installation ECS001WC

—RHD model—

PCIB0770E

1. Clutch pedal assembly 2. Assist spring 3. Bushing

4. Stopper rubber 5. Clevis pin 6. Bushing
7. Stopper rubber 8. Pedal stopper bolt 9. Snap pin

—LHD model—

PCIB0771E

1. Clutch pedal assembly 2. Assist spring 3. Bushing

4. Clevis pin 5. Bushing 6. Stopper rubber
7. Pedal stopper bolt 8. Stopper rubber 9. Snap pin
10. Bracket

NOTE:
Install clutch pedal assembly and check to see clevis pin floats freely in bore of clutch pedal.
INSPECTION AFTER REMOVAL
● Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
● Check assist spring for settling. If settling is found, replace assist spring.

CL-6
 CLUTCH FLUID

CLUTCH FLUID PFP:00017

A
Air Bleeding Procedure ECS008B9

CAUTION:
● Monitor clutch fluid level in reservoir tank to make sure it B
does not empty.
● Do not spill clutch fluid onto painted surfaces. If it spills,
wipe up immediately and wash the affected area with water. CL
● Bleed the air of operating cylinder.
1. Fill master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve. D
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve. SCIA1098E E
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in the F
clutch fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-10,
"Removal and Installation" . G

H
SCL839

CL-7
 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ECS008BA

—RHD model—

PCIB0763E

1. Nipple 2. Clamp 3. Hose

4. Cylinder body 5. Seat 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin

—LHD model—

PCIB0764E

1. Nipple 2. Clamp 3. Hose

4. Cylinder body 5. Seat 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin

REMOVAL
1. Using one of the following methods, remove hose from nipple.

CL-8
 CLUTCH MASTER CYLINDER

●Drain clutch fluid from reservoir tank and remove hose.

●Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip- A
ping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the B
affected area with water.
2. Using a flare nut torque wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal. CL
4. First remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehi-
cle.
D
INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
2. Install master cylinder assembly and tighten mounting nut to the specified torque. Refer to CL-8,
E
"Removal and Installation" .
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Refer to CL-11,
"Removal and Installation" .
4. Attach clevis of clevis pin to clutch pedal. F
5. Attach snap pin to clevis pin.
6. Install hose to nipple.
G
7. After completing this procedure, inspect and adjust pedal height and then bleed clutch tube. Refer to CL-
5, "On-Vehicle Inspection and Adjustment" , CL-7, "Air Bleeding Procedure"
Disassembly and Assembly ECS008BB H
DISASSEMBLY
1. Remove spring pin, nipple and seal from cylinder body using a
pin punch. I
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove seat.
4. Remove stopper ring and stopper. Remove push rod from cylin- J
der body while holding it securely to reduce possibility of the pis-
ton popping out.
5. Remove piston assembly and return spring. K

PCIB0274E

L
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
● Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
M
● Damaged or deformed nipple or reservoir tank
● Settling of spring
● Cracked or deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of cylinder body, sliding surface of piston assembly, and piston
cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install seat.
4. Install clevis to push rod and tighten lock nut to the specified torque. Refer to CL-8, "Removal and Installa-
tion" .
5. Install seal and nipple to cylinder body. Install spring pin, using a pin punch.

CL-9
 OPERATING CYLINDER

OPERATING CYLINDER PFP:30620

Removal and Installation ECS008BC

PCIB0765E

1. Air bleeder valve 2. Copper washer 3. Union bolt

4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring

REMOVAL
1. Drain clutch fluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Remove clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolt and remove operating cylinder from vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
● Install hose with care so that it will not be bent or twisted.
● After completing the procedure, bleed clutch tube. Refer to CL-7, "Air Bleeding Procedure" .
Disassembly and Assembly ECS008BD

DISASSEMBLY
● Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
● Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
● Settling of the spring
● Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.

CL-10
 CLUTCH PIPING

CLUTCH PIPING PFP:30650

A
Removal and Installation ECS008BE

CL

PCIB0813E

1. Clutch tube 2. Lock plate 3. Clutch hose E

4. Operating cylinder 5. Clutch pedal 6. Master cylinder

Carefully observe the following steps during clutch tube removal and installation.
F
● Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
● To fix clutch hose on the bracket, position clutch hose clasp on
the bracket locating emboss and drive lock plate vertically from G
above. Be careful not to bend or twist clutch hose. Do not
scratch or damage clutch hose.
● Tighten clutch tube flare nut to the specified torque. Refer to CL- H
11, "Removal and Installation" .
● Tighten clutch hose union bolt to the specified torque. Refer to
CL-11, "Removal and Installation" . I
CAUTION:
Do not reuse the copper washer.
PCIB0812E
● After installation, bleed clutch tube. Refer to CL-7, "Air Bleeding J
Procedure" .

CL-11
 CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISM PFP:30502

Removal and Installation ECS008BF

PCIB0767E

1. Dust cover 2. Withdrawal lever 3. Retainer spring

4. Release bearing

REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation" .
2. Remove release bearing, withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove retainer spring from withdrawal lever.
INSPECTION AFTER REMOVAL
● If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
● If contact surface of withdrawal lever is excessively worn,
replace it.
● If dust cover is cracked, replace it.

SCL733

INSTALLATION
CAUTION:
● Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
● Be careful not to bring any grease into contact with the clutch disk facing, pressure plate surface,
or flywheel surface.

CL-12
 CLUTCH RELEASE MECHANISM

1. Following the instructions below, apply grease to the specified points.

A

CL

SCL815 D
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
● Evenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring slid- E
ing surface.
● Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of the release
bearing. The grease surface should be level with the surrounding area. F
● Apply a thin coat of recommended grease evenly to the release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
2. Install in the reverse order of the removal. G

CL-13
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100

Removal and Installation ECS008BG

—QR engine model—

PCIB0768E

1. Flywheel 2. Clutch disc 3. Clutch cover

—YD engine model—

PCIB0769E

1. Flywheel 2. Clutch disc 3. Clutch cover

CAUTION:
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation"
2. Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.

CL-14
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

INSPECTION AND ADJUSTMENT AFTER REMOVAL

Clutch Disc A
● Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.
B
Runout limit/diameter of the area to be measured:
1.0 mm (0.039 in) or less/230 mm(9.06 in) dia.
● Measure clutch disc spline and input shaft spline backlash at the CL
circumference of the disc. If outside the specification, replace.
Maximum allowable spline backlash:
D
1.0 mm (0.039 in)
SCL221

● Using calipers, measure the depth to the clutch disc facing rivet E
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
Facing wear limit (depth to the rivet head): F
0.3 mm (0.012 in)

SCL229 H
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height I
using a diaphragm adjusting wrench.
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in) J

Tool number : ST 20050240

● Check clutch cover thrust ring for wear or breakage. If wear or K
breakage is found, replace clutch cover assembly.
NOTE: PCIB0276E
● Worn thrust ring will generate a beating noise when tapped at L
the rivet with a hammer.
● Broken thrust ring will make a clinking sound when cover is shaken up and down.

● If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, M
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
Allowable flywheel runout:
Vehicles with QR engine models:
Refer to EM-108, "FLYWHEEL DEFLECTION (M/T
MODELS)" .
Vehicles with YD engine models:
AEM100
Refer toEM-235, "FLYWHEEL DEFLECTION" .
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).

CL-15
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

INSTALLATION
1. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
Engine type Tool number
QR engine KV30101600
YD engine ST20630000
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure. Refer to CL-14, "Removal and Instal-
lation" .
4. Install manual transaxle. Refer to MT-17, "Removal and Installa- SCIA0909E
tion" .

CL-16
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Clutch Control System ECS008BH

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS008BI

Inner diameter 15.87 mm (5/8 in)

CL
Clutch Operating Cylinder ECS008BJ

Inner diameter 19.05 mm (3/4 in)

D
Clutch Disc ECS008BK

Engine type QR20DE QR25DE YD22DDTi

Model 240
E

Facing size
240 mm x 160 mm x 3.5 mm (9.45 in x 6.30 in x 0.138 in)
(outer dia. x inner dia. x thickness)
F
7.70 - 8.10 mm (0.303 -
7.90 - 8.30 mm (0.3110 - 0.3268 in) with 5,688 N (580 kg,
Thickness of disc assembly with load 0.319 in) with 7,845N (800
1,279lb)
kg, 1,764 lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in) G
Runout limit/diameter of the area to be
1.0 mm (0.039 in) or less/ 230 mm (9.06 in) dia.
measured
H
Maximum spline backlash
1.0 mm (0.039 in)
(at outer edge of disc)

Clutch Cover ECS008BL

I
Engine type QR20DE QR25DE YD22DDTi
Model 250
J
Set-load 4,903 N (500 kg, 1,103 lb) 5,884 N (600 kg, 1,323 lb) 7,845 N (800 kg, 1,764 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.457 - 1.535 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less K

CL-17
SERVICE DATA AND SPECIFICATIONS (SDS)

CL-18