Except for K9K : Exploded View

HR16DE

1. Flywheel
2. Clutch disc
3. Clutch cover
4. Input shaft

A. First step
B. Final step

: N·m (kg-m, ft-lb)
: Apply lithium-based grease
including molybdenum disulphide.

MR16DDT

1. Flywheel 2. Clutch disc 3. Clutch cover 4. Input shaft

A. First step B. Final step

: N·m (kg-m, ft-lb)
: Apply lithium-based grease
including molybdenum disulphide.

Except for K9K : Removal and Installation

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage a seal of CSC and may cause clutch fluid leakage. Refer to CL-27, "Removal and Installation".

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.

• Never clean clutch disc using solvent.

REMOVAL

1. Remove transaxle assembly. Refer to TM-30, "Removal and Installation" (RS5F92R), or TM-84, "MR16DDT : Removal and Installation" (RS6F94R).

2. Remove clutch cover mounting bolts while holding clutch cover.

CAUTION:
Never drop clutch disc.

3. Remove clutch cover and clutch disc.

CAUTION:
Never drop clutch disc

.

INSTALLATION

1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

2. Apply recommended grease to clutch disc (1) and input shaft (2) splines (A).

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 judder. And if it adheres to seal of CSC, it cause clutch fluid leakage. Wipe out excess grease. Wipe out any grease oozing from the parts

.

3. Install clutch disc, using a clutch aligner (A) [Commercial service tool].

4. Install clutch cover, and then temporarily tighten clutch cover mounting bolts.

5. Tighten clutch cover mounting bolts to the specified torque evenly in two steps in the numerical order as shown in the figure.

6. For the next step and after, install in the reverse order of removal.

Except for K9K : Inspection

NSPECTION AFTER REMOVAL

Clutch Disc

• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to be measured : Refer to CL-35, "Clutch Disc".

• Measure backlash to clutch disc spline and main drive gear spline at the circumference of clutch disc. If it is outside the specification, replace clutch disc.

Maximum allowable spline backlash (at outer edge of disc) : Refer to CL-35, "Clutch Disc".

• Measure the depth “A” to clutch disc facing rivet heads, using a calipers. If it exceeds the allowable wear limit, replace clutch disc.

Facing wear limit (depth to the rivet head) “A” : Refer to CL-35, "Clutch Disc".

Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.

NOTE

:
• Worn thrust ring will generate a beating noise when tapped at 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, repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

INSPECTION AFTER INSTALLATION

Clutch Cover Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height, using the diaphragm adjusting wrench (A) [SST: ST20050240].

Tolerance for diaphragm spring lever unevenness : Refer to CL-36, "Clutch Cover".

K9K : Exploded View

1. Flywheel
2. Clutch disc
3. Clutch cover
4. Input shaft

A. First step B. Final step

: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)

K9K : Removal and Installation

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage a seal of CSC and may cause clutch fluid leakage. Refer to CL-27, "Removal and Installation".

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.

• Never clean clutch disc using solvent.

REMOVAL

1. Remove transaxle assembly. Refer to TM-86, "K9K : Removal and Installation".

2. Remove clutch cover mounting bolts while holding clutch cover.

CAUTION:
Never drop clutch disc.

3. Remove clutch cover and clutch disc.

CAUTION:
Never drop clutch disc.

INSTALLATION

1. Clean clutch disc and input shaft splines to remove powder arisen from abrasion.

2. Install clutch disc, using a clutch aligner (A) [Commercial service tool].

3. Install clutch cover, and then temporarily tighten clutch cover mounting bolts.

4. Tighten clutch cover mounting bolts to the specified torque evenly in two steps in the numerical order as shown in the figure.

5. For the next step and after, install in the reverse order of removal.

K9K : Inspection

INSPECTION AFTER REMOVAL

Clutch Disc
• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to be measured : Refer to CL-35, "Clutch Disc".

• Measure backlash to clutch disc spline and main drive gear spline at the circumference of clutch disc. If it is outside the specification, replace clutch disc.

Maximum allowable spline backlash (at outer edge of disc) : Refer to CL-35, "Clutch Disc".

• Measure the depth “A” to clutch disc facing rivet heads, using a calipers. If it exceeds the allowable wear limit, replace clutch disc

Facing wear limit (depth to the rivet head) “A” : Refer to CL-35, "Clutch Disc".

Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.

NOTE

:
• Worn thrust ring will generate a beating noise when tapped at 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, repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

INSPECTION AFTER INSTALLATION

Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height, using the diaphragm adjusting wrench (A) [SST: ST20050240].

Tolerance for diaphragm spring lever unevenness : Refer to CL-36, "Clutch Cover".