GROUP-6

CLUTCH.
CONTENTS

SPECIFICATIONS ............. .; ................................. 2 SERVICE ADJUSTMENT PROCEDURES ............. 4 E

GENERAL SPECIFICATIONS .......................... 2 CLUTCH PEDAL INSPECTION

AND ADJUSTMENT . . .. . . .. .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS ............................ 2 BLEEDING . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . .. .. .. . . . . .. .. . . . . . . . . . . 4
TORQUE SPECIFICATIONS ............................ 2
COMPONENT SERVICE ........................................ 5
LUBRICANTS ................................................... 3
CLUTCH ASSEMBLY ........................................ 5
TROUBLESHOOTING .......................................... 3 CLUTCH CONTROL ......................................... 8

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an SPECIFICATIONS

GENERAL SPECIFICATIONS

Clutch operating method Hydraulic type

Inside diameter of clutch master cylinder mm (in.) 15.87 (.62)
Clutch disc
We Single dry disc type
Facing diameter (outside x inside) mm (in.) 225 x 150 (8.86 x 5.91)
Number of torsion springs 4
Spline inside diameter mm (in.) 23.16-23.21 (.912-.914)
Clutch cover assembly
Type Diaphragm spring, strap rivet We
Setting load N (lbs.) 3,432 (772)
Mounting bolt circle diameter mm (in.) 264 (10.39)
Clutch release bearing
Type Angular contact, self-centering type
Free travel mm (in.) 1.6 (.06)
Clutch release cylinder
Cylinder bore diameter mm (in.) 19.05 (.75)

SERVICE SPECIFICATIONS mm (in.)

Standard value
Clutch pedal height 186-191 (7.3-7.5)
Clutch pedal free play 5-10 (.2-.4)
Clearance between clutch pedal and 35 (1.4) or more
floorboard when pedal is depressed
Service limit
Clutch disc
Rivet sink 0.3 (.012)

TORQUE SPECIFICATIONS Nm (ft.lbs.)

Clutch to flywheel 15-21 (11-15)

Flywheel to crankshaft 128-137 (94-101)
Release cylinder to transmission case 3041 (22-30)
Transmission to engine 43-53 (32-39)
Fulcrum 3041 (22-30)
Clutch pedal to pedal bracket 25-35 (18-25)
Eye bolt 20-25 (15-18)
Clutch tube flare nut 13-17 (10-12)
Clutch master cylinder to firewall 7-9 (5-7)
Clutch pedal bracket 8-12 (6-9)
Push rod lock nut 8-12 (6-9)

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 SPECIFICATl0NS/TROUBLESHOOTING alE
LUBRICANTS

Specified lubricants Quantity

Fluid Brake fluid DOT 3 As required

Grease for clutch pedal shaft, Multipurpose grease As required
bushings, and return spring SAEJ3 1Oa, NLGI grade $3

TROUBLESHOOTING
Symptom Probable cause Iiemedy

Clutch slips Insufficient clutch pedal free play Lidjust

Oil or grease on clutch facing Iieplace

Clutch facing worn
Pressure spring deteriorated

Pressure plate or flywheel runout 1bpair or replace

Hydraulic system failure

Clutch drags or does not release Excessive clutch pedal free play I4djust

Interference between pedal and floor panel (Zorrect

r
Pilot bearing worn or broken Replace
Clutch disc warped
Pressure plate, disc or throwout bearing
damaged

Hydraulic system failure Repair or replace

Clutch chatters Facing hardened Replace

Facing stained with oil or grease
Weak or broken disc damper springs
Improper facing contact or disc runout
Pressure plate or flywheel warped

Loose engine mounting Repair or replace

Clutch noises Release bearing broken, worn or poorly Replace

lubricated
Pilot bearing worn
Disc hub loose
Disc plate cracked
Torsion springs deteriorated or broken

Clutch operation erratic or roug h Facing stained with grease or oil Replace
Facing worn or rivet loose
Torsion spring deteriorated or broken

Insufficient lubricant on clutch pedal pivot Lubricate

6-3
aE SERVICE ADJUSTMENT PROCEDURES

CLUTCH PEDAL INSPECTION AND ADJUSTMENT

1. Measure the clutch pedal height and free play.

Clutch pedal height A . . . . 186-191 :mm (7.3-7.5 in.)

Clutch pedal free play B . . . . . . . 5- 10 mm (.2-,.4 in.)

.’ -

NOTE
The clutch pedal is so made that no adjustment of free play is
possible.
2. If the clutch pedal height and free play are not within the
standard value, adjust as follows:
(1) Turn the pedal stopper bolt back to a position where
it does not contact the pedal arm. (OSW503)
(2) Loosen the push rod lock nut and adjust the pedal
height to the standard value by turning the push rod.
(OSYOO7)
(3) Turn the pedal stopper bolt until it comes into
contact with the pedal arm, and then tighten the lock
nut.
3. After making the adjustment, depress the clutch pedal
several times and check the clutch pedal to: floorboard
clearance is within the standard value range when the
clutch is disengaged.

Pedal to floorboard clearance C when pedal is de-

pressed . . . . . . . . . . . . . . . . 35 mm (1.4in.) ormore
4. If the clutch pedal to floorboard clearance ,is less than
the standard value, air mixture in hydraulic system or
defective clutch assembly is suspected.
Bleed the hydraulic system or repair the clutch assembly.

BLEEDING
Whenever the clutch tube, the clutch hose, and/o:r the clutch
master cylinder have been removed, or if the clutch pedal is
spongy, bleed the system.
1. Loosen the bleeder screw at the clutch release cylinder.
2. Push clutch pedal down slowly until all air is expelled.
3. Hold clutch pedal down until bleeder screw is retightened.
4. Refill clutch master cylinder with recommended brake
fluid.
Caution
Use the recommended brake fluid. Avoid using a mixture. of
the recommended fluid and other fluid.

Recommended brake fluid . . . . . . . . . . . . . .‘. DOT 3

6-4
 COMPONENT SERVICE-CLUTCH ASSEMBLY
alI

COMPONENTS

ii

1. Flange bolt - MlOx40 (2)

2. Flange bolt - MlOx65 (2)
3. Transmission assembly
4. Bolt - MlOx30 (2)
5. Clutch release cylinder
6. Release fork boot
7. Return clip (2) Clutch cover assembly
8. Clutch release bearing
9. Release fork
10. Fulcrum
11. Bolt (6)
12. Clutch cover assembly
13. Clutch disc

NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.

Nm ft.lbs.

A 43-53 32-39
B 30-41 22-30
C 30-41 22-30
D 15-21 II-15 Release fork

Clutch release cylinder

6CLO12

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am
REMOVAL
COMPONENT SEFIVICE-CLUTCH ASSEMBLY

1. Insert a universal clutch alignment tool, or the main drive

gear of transmission in center spline to prevent dropping
of clutch disc.
2. Loosen bolts that hold clutch cover assembly diagonally
one by one and remove clutch cover assembly.
Caution
DO NOT clean clutch disc or release bearing with cleaning
solvent.

6CL008

3. Slide release fork in direction indicated by arrow to

disengage fulcrum from clip. Attempting to remove
release fork by sliding it in other direction will result in
damage to clip.

Sliding direction

DC LO02

INSPECTION
Clutch Disc
Check facing for wear. Replace excessively worn facing. Wear
is measured from facing surface to rivet head. (6CLOO3)

Clutch disc (rivet sink) [Service limit] .... ... ...

0.3 mm (.012 in.)

Clutch Cover Assembly

Inspect diaphragm spring for excessive wear of fingers and
looseness of strap rivets, and inspect pressure pla.te for scor-
ing. Replace if damage is evident.
Release Bearing and Release Fork
1. Check the release bearing for rough rotatio:n or abnor-
mal noise. Check the diaphragm spring contacting por-
tions for abnormal wear.
2. Check the bearing and fulcrum cbntacting portions of the
release fork for abnormal wear.

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 COMPONENT SERVICE-CLUTCH ASSEMBLY aln

INSTALLATION
1. Pack the release fork fulcrum hole and release cylinder Release bearing I
push rod hole with grease. (DCLOOS)
2. Pack grease into groove on release bearing I.D.
3. If there is oil or grease on clutch facing or pressure plate,
thoroughly wipe away with a dry shop towel.
4. Lightly grease clutch disc spline and main drive gear
spline of transmission.

5. Using a universal clutch alignment tool, or the main drive

gear of transmission, install clutch disc and clutch cover
assembly on to flywheel. (6CLOO4)
6. When installing clutch disc, be sure that surface having
manufacturer’s stamped mark is on pressure plate side.
Caution
When installing transmission, do not shake it or install in
such a manner that main drive gear is stressed unduly. Make
sure that main drive gear enters clutch disc squarely.

6C LOO4
J

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am
COMPONENTS
COMPONENT SERVICE-CLUTCH CONTROL

Clutch Pedal ,

1. Pedal shaft
2. Bushing
3. Spacer
4. Clutch pedal bracket
5. Clutch pedal 5----
6. Return spring
7. Stopper bolt
6
8. Lock nut

Nm ft.lbs.

A 25-35 18-25
B 8-12 6-9

Clutch Master Cylinder and Tube

1. Reservoir cap
2. Reservoir
3. Clutch master cylinder
4. Sealer
5. Piston assembly
6. Piston stop ring
7. Piston boot
8. Damper and push rod assembly
9. Clutch tube
10. Clutch hose.
11. Gasket
12. Eye bolt

Nm ft.lbs.

A 20-25 15-18
05w501
B 1317 ‘10-12
C 7-9 5-7
D 8-12 6-9

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 COMPONENT SERVICE-CLUTCH CONTROL

REMOVAL
1. Loosen the bleeder screw of the release cylinder and
drain the brake fluid.
2. Disconnect the push rod from the clutch pedal. (OSWSO3)
3. Remove the clutch pedal from the pedal bracket.

4. Disconnect the clutch tube from the master cylinder.

5. Remove the master cylinder. (OSW.502)

6. Disconnect the clutch hose from the clutch tube and

release cylinder. (OSW504)
7. Remove the clutch tube.

I OBW504

INSPECTION
1. Check sealer for damage.
2, Check master cylinder or clutch hose for fluid leakage.
3. Check clutch hose and tube for cracks or clogging.
4. Check pedal shaft bushings for wear.
5. Check pedal arm for bending and twisting.
6. Check return sfiring for weakening.

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an COMPONENT SERVICE-CLUTCH CONTROL

MASTER CYLINDER OVERHAUL

Disassembly
1. Remove the piston stop ring. (YO8034)
2. Remove the piston assembly.
Caution
Use care not to damage the master cylinder body and piston
assembly.
Do not disassemble the piston assembly.

Inspkction
1. Check inside cylinder body for rust or scoring.
2. Check piston cup for wear or deformation.
3. Check piston for rust or scoring.
4. Check clutch tube inside connecting section for clogging.
Reassembly
Apply, specified brake fluid to the inner surpce of the
cylinder and to the entire periphery‘of the piston assembly.
(Y085 17)

Recommemded brake fluid . . . . . . . . . . . . . . DOT 3

I Yrl8517

INSTALLATION
1. After tightening the clutch tube flare nut and eye bolt,
check to be sure there is no leakage of the clutch fluid.
2. Apply specified multipurpose grease to the pedal shaft
and bushings. (Y085 19)

Recommended multipurpose grease . . . . . . . . ., . . .

SAEJ3 1Oa, NLGI grade #3

Y08519

3. Temporarily tighten the flare nut by hand, and then

tighten it to the specified torque, being careful that the
clutch hose does not become twisted. (OSW50’7)

Clutch tube flare nut tightening torque . . . . . . . . .

13-l 7 Nm ( 1O-l 2 ftlbs.)

Secured side

08W507

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 COMPONENT SERVICE-CLUTCH CONTROL an

4. Connect the clutch hose to the release cylinder at the

stepped portion shown in the illustration. (OSWSO8)
5. Torque all parts to specifications during assembly,
6. Bleed the air from the system. (Refer to p. 6-4.)
7. Adjust the clutch pedal height. (Refer to p. 6-4.)

08W501

CLUTCHRELEASECYLINDER
Removal and Disassembly
1. Remove eye bolt and gaskets and disconnect clutch hose
from clutch release cylinder.
2. Remove two bolts securing the clutch release cylinder
and clutch housing and remove clutch release cylinder
assembly.
3. Remove the boot and push rod and take out piston and
spring.
Inspection
1. Check inside cylinder body for rust or scoring.
2. Check piston cup for wear or deformation.
3. Check piston for rust or scoring.
Reassembly and Installation 1
1. Insert spring into release cylinder.
Apply brake fluid
2. Apply brake fluid to outer surface of piston, piston cup
and cylinder bore. (DCL006)
3. Install the piston and piston cup into the release cylinder.
4. Install push rod and boot.
5. Install release cylinder to clutch housing and tighten two
bolts to specified torque.
6. Connect clutch hose to release cylinder and tighten eye
bolt.
7. Bleed the air from the system. (Refer to p. 6-4)
DCLOOG

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