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U-145/173 BL2,3

SECTION 5C

CLUTCH

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a

tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unlessotherwise noted.

TABLE OF CONTENTSDescription and Operation 5C--2. . . . . . . . . . . . . . . . .

General Description 5C--2. . . . . . . . . . . . . . . . . . . . . .

Component Locator 5C--3. . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Clutch Components 5C-- 3. . . . . . . . . . . . . .

Diagnostic Information and

Procedures 5C--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clutch Operation 5C--6. . . . . . . . . . . . . . . . . . . . . . . . .

Repair Instructions 5C--8. . . . . . . . . . . . . . . . . . . . . . . .

On Vehicle Service 5C--8. . . . . . . . . . . . . . . . . . . . . . . .

Clutch pedal 5C--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Disc and Related Components 5C--9. . . . . . .

Clutch Pedal Adjustment (Hydraulic) 5C--11. . . . . . .

Clutch Release Point Adjustment (Hydraulic) 5C--12

Air Bleeding 5C--13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Master Cylinder Assembly 5C--13. . . . . . . . . .

Clutch Release Cylinder Assembly 5C--14. . . . . . . . .

Clutch Reservoir 5C--15. . . . . . . . . . . . . . . . . . . . . . . .

Unit Repair 5C--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clutch Master Cylinder 5C--16. . . . . . . . . . . . . . . . . . .

Clutch Release Cylinder 5C--16. . . . . . . . . . . . . . . . . .

Specification 5C--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastener Tightening Specification 5C--18. . . . . . . . . .

Special Tools and Equipment 5C--18. . . . . . . . . . . . .

Special Tools Table 5C--18. . . . . . . . . . . . . . . . . . . . . .

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5C -- 2 CLUTCH

U-145/173 BL2,

DESCRIPTION AND OPERATION

GENERAL DESCRIPTIONNotice: Refer to Clutch Hydraulic System Lubricant No-

tice in Cautions and Notices.

Driving Members

The driving members consist of two flat surfaces ma-

chined to a smooth finish. One of these is the rear faceof the engine flywheel, and the other is the pressureplate. The pressure plate is fitted into a steel cover,which is bolted to the flywheel.

Driven Members

The driven member is the clutch disc with a splined hubwhich is free to slide lengthwise along the splines of the

input shaft, but which drives the input shaft throughthese same splines.

The driving and driven members are held in contact byspring pressure. This pressure is exerted by a dia-phragm spring in the pressure plate assembly.

Operating Members

The clutch release system consists of the clutch pedal,the clutch shaft, the fork, and the release bearing.

When pressure is applied to the clutch pedal, the forkpivots on its shaft and the inner end pushes against therelease bearing. The bearing then pushes against therelease levers in the pressure plate assembly, therebyreleasing the clutch.

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CLUTCH 5C -- 3

U-145/173 BL2,3

COMPONENT LOCATOR

HYDRAULIC CLUTCH COMPONENTS

Clutch Release Cylin der/ Lever(Left --Hand Drive Shown , Right --Hand Drive Similar)

UAA5C010

1. Master Cylinder2. Clutch Reservoir3. Reservoir Hose4. Spring Clamp5. Release Cylinder Assembly6. Release Cylinder7. Release Cylinder Bracket8. Release Hose

9. Hydraulic Clutch Pipe10. Clamp11. Release Lever12. Bushing

13. Pin14. main shaft Oil Seal15. Bolt16. Release Bearing17. Bearing Guide Sleeve18. O--Ring19. Input Shaft Seal20. Screw Plug

21. Magnet22. Release pork23. Back up lamp switch24. washer

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5C -- 4 CLUTCH

U-145/173 BL2,

Clutch Pedal

UAA5C020

1. Clutch Pedal Brace2. Nut

3. Washer Spring4. Turn Over Spring5. Spring Bushing6. Bushing7. Pedal Brace Bracket

8. Bolt9. Clutch Pedal Shaft

10. Clutch Pedal11. Pedal Plate Cover12. Pin13. Bushing14. Bushing

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CLUTCH 5C -- 5

U-145/173 BL2,3

Clutch Disc

A103C003

1 Flywheel2 Clutch Disc

3 Pressure Plate4 Release Bearing

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5C -- 6 CLUTCH

U-145/173 BL2,

DIAGNOSTIC INFORMATION AND PROCEDURES

CLUTCH OPERATION

Fails to Release

Checks Action

DEFINITION: When the pedal is pressed to the floor, the shift lever does not move freely in and out of reversegear.

Check for a loose linkage. Repair or replace loose linkage, if necessary.

Check for a damaged clutch disc. Replace the damaged clutch disc.

Check for an improperly installed fork shaft. Remove and properly reinstall the fork shaft. Verylightly lubricate the fork fingers at the release bearingwith wheel bearing grease.

Check for the clutch disc hub binding on the inputshaft splines.

Repair or replace the clutch disc hub.

Check for a warped or bent clutch disc. Replace the warped or bent clutch disc.

Slipping

Checks Action

Check for the driver improperly operating the vehicle. Correct the drivers operation of the vehicle as neces-sary.

Check for an oil--soaked clutch disc. Correct the leak at its source and install a new clutchdisc.

Check for worn facing or facing torn from the disc. Replace the worn disc with a new disc.

Check for warped pressure plate or a warped flywheel. Replace the pressure plate.

Check for a driven plate that is not seated. Start the engine 30 to 40 times. Do not overheat theengine.

Check for a driven plate that is overheated. Allow the driven plate to cool.

Grabbing (Chattering)

Checks Action

Check for burned or glazed facing caused by oil on thefacing.

Correct the leak at its source and install a new clutchdisc.

Check for worn splines on the input shaft.v Replace the worn input shaft.

Check for a warped pressure plate or a warped fly-wheel.

Replace the warped pressure plate or the warped fly-wheel.

Check for burned or smeared resin on the flywheel orthe pressure plate.

Sand off the burned or smeared resin if it is superficial.Replace any or heat--checked parts.

Rattl ing (Transaxle Click)

Checks Action

Check for weak retracting springs. Replace the pressure plate.

Check for a loose release fork. Remove and reinstall the release fork properly.

Check for oil in the driven plate damper. Correct the cause of the oil leak and replace the driv-en disc.

Check for a damaged driven plate damper spring. Replace the driven disc.

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CLUTCH 5C -- 7

U-145/173 BL2,3

Release Bearing Noise with Clutch Fully Engaged

Checks Action

Check for the driver improperly operating the vehicle. Correct the drivers operation of the vehicle as neces-sary.

Check for a binding release bearing. Clean and re-lubricate the release bearing. Inspect therelease bearing for burrs and nicks.

Check for an improperly installed release lever. Remove and reinstall the release lever properly.

Check for a weak linkage return spring. Replace the weak linkage return spring.

Noise

Checks Action

Check for a worn release bearing. Replace the worn release bearing.

Check for an improperly installed release lever. Remove and properly reinstall the fork shaft. Verylightly lubricate the fork fingers at the release bearingwith wheel bearing grease.

Pedal Stays on Floor When Disengaged

Checks Action

Check for binding in the linkage or the release bearing. Lubricate and freeup the binding linkage or the releasebearing.

Check for weak pressure plate springs. Replace the pressure plate.

Hard Pedal Effort

Checks Action

Check for binding in the linkage. Lubricate and free-up the binding linkage.

Check for a worn driven plate. Replace the worn driven plate.

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5C -- 8 CLUTCH

U-145/173 BL2,

REPAIR INSTRUCTIONS

ON VEHICLE SERVICE

A103C049

CLUTCH PEDAL

(Left --hand Driv e Shown, Righ t --handDrive Similar)

Removal and Installation Procedure

1. Disconnect the negative battery cable.

Caution: Refer to Battery Disconnect Caution in Cau-tions and Notices.

2. Disconnect the return spring from the mount brace.

A103C036

3. Remove the nut, the washer, and the pedal mount-ing shaft.

Installation NoticeNotice: Refer to Fastener Notice in Cautions and No-

tices.

Tightening Torque 18Nm(13lb--ft)

A103C067

4. Remove the locking washer and the piston rod bolt.

5. Remove the clutch pedal with the return spring fromthe vehicle.

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CLUTCH 5C -- 9

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A103C025

CLUTCH DISC AND RELATEDCOMPONENTSTools Required

J--36547 Input Shaft Seal Installer

J--42474 Clutch Arbor or Equivalent




2. Raise and suitably support the vehicle.

Notice: Refer to Vehicle Lifting and Jacking Notice in

Cautions and Notices.

3. Remove the left front wheel. Refer to Section 2E,Tires and Wheels.

4. Remove the engine under covers. Refer to Section9N, Frame and Underbody.

5. Remove the transaxle from the vehicle. Refer toSection 5B. Five--Speed Manual Transaxle.

6. Remove the pressure plate bolts and the pressureplate. Support the pressure plate when you removethe last bolt.

A103C044

Adjustment Notice :

D Coat the spline on the clutch disc with multi-purposegrease.

D Align the pressure plate and the clutch disc onto the

flywheel using the clutch arbor J--42474.


tices.


A103C026

7. Remove the clutch disc.

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5C -- 10 CLUTCH

U-145/173 BL2,

A103C027

8. Remove the release fork bolt.

Installation Notice


A103C028

9. Pull the clutch release shaft upward, out of thetransaxle.

A103C029

10. Remove the fork and the release bearing from therelease bearing guide sleeve.

Installation Notice

D Coat the release bearing bore with multi-purposegrease.

A103C033

11. Remove the release lever shaft bushings.

Installation Notice

D Coat the bushing bores with multi-purpose grease.

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CLUTCH 5C -- 11

U-145/173 BL2,3

A103C030

12. Remove the release bearing guide sleeve bolts andthe release bearing guide sleeve.

Installation Notice

Tightening Torque 5Nm(45lb--in)

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

A103C031

13. Remove the input shaft seal from the release bear-ing guide sleeve.

Installation Notice

D Install the input shaft seal into the release bearingguide sleeve. Use input shaft seal installer J--36547with a hammer.

A103032

14. Remove the O-ring from the groove in the transaxlecase.

15. Installation should follow the removal procedure inthe reverse order.

A103C010

CLUTCH PEDAL ADJUSTMENT(HYDRAULIC)

(Left --Hand Drive Shown , Righ t --HandDrive Similar)

Adjustment Procedure

1. Determine the clutch pedal play. Depress the clutchpedal lightly with your hand and measure thedistance when you feel resistance.

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5C -- 12 CLUTCH

U-145/173 BL2,

A103C051

2. Adjust the clutch pedal play. Loosen the lock nut andturn the pushrod. Clutch pedal play should measure6 to12 mm (0.2 to 0.5 inch). Tighten the locknut afteradjustment.

A103C038

3. Measure the clutch pedal travel. Press the clutchpedal all the way to the floor. Measure from thestarting position to the ending position.

A103C039

4. Adjust the clutch pedal travel. Loosen the locknutand turn the bolt. Clutch pedal travel should mea-sure more than 130 mm (5.1 inches). Tighten thelocknut after adjustment.

A103C001

CLUTCH RELEASE POINTADJUSTMENT (HYDRAULIC)

Adjustment Procedure

1. Apply the parking brake.

2. Run the engine at idle speed.

3. While you move the shift lever into the reverse posi-tion, depress the clutch pedal slowly and measurethe distance between the point when gear noise isnot heard and the point the clutch pedal is complete-ly depressed. The distance should be more than 30mm (1.2 inches).

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CLUTCH 5C -- 13

U-145/173 BL2,3

4. If the distance is not more than 30 mm (1.2 inches),check the following:

D Clutch pedal height

D Clutch pedal play

D Air in the system

D Clutch cover and disk

A103C013

A103C046

AIR BLEEDINGNotice:Refer to Clutch Fluid Noticein Cautions and No-

tices.

Notice: Bleed the hydraulic system to remove the airwhich entered when the pipes were disconnected for re-

pairs. The clutch/brake fluid in the clutch/brake reservoirmust be maintained at the MIN level or higher during airbleeding. Right-hand drive vehicles use a separateclutch fluid reservoir.

1. Attach a vinyl hose to the bleeder plug. Place theother end of the vinyl tube in a glass container half--filled with brake fluid.

2. Slowly pump the clutch pedal several times.

3. While you press the clutch pedal, loosen the bleederscrew until the fluid starts to run out. Close thebleeder screw.

4. Repeat Step 3 until there are no air bubbles in the

fluid.5. Fill the reservoir with clutch fluid up to the MAX lev-

el.

CLUTCH MASTER CYLINDERASSEMBLY

(Left- Hand Drive Shown, Right - Hand Drive Similar)


Notice: Before disconnecting the reservoir tank hose,remove the clutch/brake fluid from the reservoir tank.Right--hand drive vehicles use a separate clutch fluidreservoir.



2. Disconnect the spring clamp on the master cylinder.Remove the reservoir hose.

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5C -- 14 CLUTCH

U-145/173 BL2,

B103C001

3. Disconnect the pipe connected to the master cylin-der.

A103C037

B103C002

B103C004

4. Remove the locking washer and the piston rod boltfrom the clutch pedal and piston rod clevis.


6. Remove the lock nuts on the master cylinder brack-et. Remove the master cylinder in the direction ofthe engine compartment.


tices.


D Bleed the air. Refer to Air bleeding in this section.

D Adjust the clutch pedal. Refer to Clutch Pedal Ad-justment in this section.


CLUTCH RELEASE CYLINDERASSEMBLYRemoval and Installation Procedure


Caution: Refer to Battery Disconnect Caution in Cau-

tions and Notices.

2. Remove the bolt and disconnect the hose from theclutch release cylinder.

Adjustment Notice:

D Bleed the air. Refer to Air bleeding in this section.

D Adjust the clutch pedal. Refer to Clutch Pedal Ad-justment (Hydraulic) in this section.

D Fill the reservoir with clutch/brake fluid up to the MAXlevel.

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CLUTCH 5C -- 15

U-145/173 BL2,3

B103C003

3. Remove the clutch release cylinder bolts and re-move the release cylinder from the transaxle.


tices.


4. Installation should follow the removal procedure in

the reverse order.

UAA5C030

CLUTCH RESERVOIR


1. Drain the clutch oil

2. Disconnect the reservoir hose and remove theclutch reservoir


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5C -- 16 CLUTCH

U-145/173 BL2,

UNIT REPAIR

A103C043

CLUTCH MASTER CYLINDER

Disassembly and Assembly Procedure

1. Remove the clutch master cylinder assembly fromthe vehicle. Refer to Clutch Master Cylinder As-

sembly in this section.2. Remove the boot and disconnect the piston stop

ring using ring pliers.

A103C048

3. Remove the push rod assembly and the piston as-sembly.

4. Inspect the clutch master cylinder wall and the pis-

ton for wear. Replace the piston if necessary.5. Inspect the cup and the piston for wear. Fluid leaks

will show wear on the cup and the piston. Replacethe cup and the piston if necessary.

6. Inspect the push rod for wear. Repair the pushrod ifnecessary.

Installation Notice

Caution: Refer to Safety Glasses Caution in Cautionsand Notices.

D Apply clean fluid to the piston assembly cup andinsert the piston assembly and the pushrod as-

sembly into the master cylinder body.7. Assembly should follow the disassembly procedure

in the reverse order.

A103C053

CLUTCH RELEASE CYLINDER

Disassembly and Assembly Procedure

1. Remove the clutch release cylinder assembly fromthe vehicle. Refer to Clutch Release Cylinder As-sembly in this section.

2. Remove the bolts and brackets.

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CLUTCH 5C -- 17

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A103C041

3. Remove the boot and the push rod.

A103C042

4. Compress the piston with a driver, and then removethe snap ring with snap ring pliers.

5. Remove the piston assembly.

6. Assembly should follow the disassembly procedurein the reverse order.

Installation Notice

Caution: Refer to Safety Glasses Caution in Cautionsand Notices.

D Apply clean clutch fluid to the piston and the cup.

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5C -- 18 CLUTCH

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Application NSm Lb-Ft Lb-In

Clutch Fork to Release Lever Shaft Bolt 35 26 --

Clutch Master Cylinder Locknuts 22 16 --

Clutch Pedal Nut 18 13 --

Pressure Plate to Flywheel Bolts 15 11 --

Release Bearing Guide Sleeve Bolts 5 -- 45

Release Cylinder Bolts 60 44 --

SPECIAL TOOLS

SPECIAL TOOLS TABLE

A103C009

J-36547Input Shaft Seal

Installer

A103C045

J-42474Clutch Arboror Equivalent

Documents

u100_sm_gen_5c