CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

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

CL-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ECS005EO

● Recommended fluid is brake fluid “DOT 3”.

● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● When removing and installing clutch piping, use Tool.
● 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
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

SBR820BA

CL-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS0055W

Tool name
Description
Tool number B

Flare nut torque wrench

CL
GG94310000 Removing and installing clutch piping
a: 10 mm (0.39 in)
D
S-NT406

E
Pin punch
Removing and installing master cylinder
ST23550000
spring pin
Tip diameter: 4.5 mm (0.177 in) dia.
F

ZZA0515D

Diaphragm spring adjusting wrench Adjusting unevenness of diaphragm spring of

ST20050240 clutch cover H

ZZA0508D

I
Clutch aligning bar
KV30101600 (New)
KV30100100 (Former) Installing clutch cover and disc J
a: 22.8 mm (0.898 in) dia. (QR engine models)
b: 15.7 mm (0.618 in) dia.
c: 12.0 mm (0.472 in) dia.
ZZA0505D K

Clutch aligning bar

ST20630000 L
Installing clutch cover and disc
a: 15.8 mm (0.622 in) dia.
(YD engine models)
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.077 in)
M
S-NT405

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-70 (QR engine models), EM-196 (YD engine models)

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) CL-15

5
PFP:00003

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
ECS005EP
 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

A
On-Vehicle Inspection and Adjustment ECS0090Y

1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch B
pedal.
a. If the pin is not free, check that the ASCD switch is not applying
pressure to the clutch pedal causing the pin to bind. To adjust,
CL
loosen ASCD switch lock nut and turn ASCD switch.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats in the bore of the D
clutch pedal. It should not be bound by the clutch pedal.
d. If the pin is still not free, remove the pin and check for defoma- PCIB0124E
tion or damage. Replace pin if necessary. Leave pin removed for
step 2. E
2. Check clutch pedal stroke for free range of movement.
a. With the clutch pedal clevis pin removed, manually move the pedal up and down to determine if it moves
freely. F
b. If any sticking is noted, replace the related parts (clutch pedal bracket, assist spring, bushing etc.) Re-
assemble the pedal and re-verfity that the clevis pin floats freely in the bore of the pedal.
G
3. Adjust clearance “C” while depressing clutch pedal fully.(With
clutch interlock switch)

H
Clearance C : 0.1 - 1.0mm (0.004 - 0.039 in)
4.
Check clutch hydraulic and system components (clutch master I
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as J
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "Air Bleeding Procedure" .
K
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. L

SCL800

CL-5
 CLUTCH PEDAL

Removal and Installation ECS005ER

—RHD models—

SCIA1882E

1. Pedal bracket assembly 2. Fulcrum pin 3. Pedal stopper bolt (Without ASCD)
4. ASCD clutch switch (With ASCD) 5. Lock nut 6. Bushing
7. Bushing 8. Snap pin 9. Stopper rubber
10. Clutch pedal 11. Bushing 12. Clevis pin
13. Stopper rubber 14. Bushing 15. Assist spring
16. Clutch switch

NOTE:
Install clutch pedal assembly and adjust the pedal height. Tighten pedal stopper bolt (or ASCD clutch switch)
to the specified torque.
INSPECTION AFTER REMOVAL
● Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal.
● Check assist spring for settling. If settling is found, replace the assist spring.

CL-6
 CLUTCH FLUID

CLUTCH FLUID PFP:00017

A
Air Bleeding Procedure ECS00561

CAUTION:
● Monitor fluid level in the reservoir tank to make sure it does B
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 operating cylinder.
1. Fill the master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to the air bleeder valve. D
3. Depress the clutch pedal slowly and fully a few times at an inter-
val of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder. 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
brake fluid.
Air bleeder: G
: 5.9 - 9.8 N·m (0.61 - 0.99 kg-m, 53 - 86 in-lb)

H
SCL839

CL-7
 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ECS00562

—RHD model—

SCIA0324E

1. Clevis pin 2. Snap pin 3. Clevis

4. Lock nut 5. Seat 6. Stopper ring
7. Stopper 8. Push rod 9. Piston assembly
10. Return spring 11. Cylinder body 12. Seal
13. Spring pin 14. Nipple 15. Clamp
16. Hose

—LHD model—

SCIA1099E

1. Clevis pin 2. Snap pin 3. Clevis

4. Lock nut 5. Seat 6. Stopper ring
7. Stopper 8. Push rod 9. Piston assembly
10. Return spring 11. Cylinder body 12. Seal
13. Spring pin 14. Nipple 15. Clamp
16. Hose

CL-8
 CLUTCH MASTER CYLINDER

REMOVAL
1. Using one of the following methods, remove hose from the nipple. A
● Drain clutch fluid from reservoir tank and remove hose.

● Remove hose from the nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from
dripping. B
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water. CL
2. Using a flare nut wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. First remove the mounting nuts on the master cylinder assembly, and then the master cylinder assembly D
from the vehicle.
INSTALLATION
E
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.
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. F
4. Attach clevis of the clevis pin to the clutch pedal.
5. Attach snap pin to the clevis pin.
6. Install hose to the nipple. G
7. After completing this procedure, inspect and adjust pedal height and then bleed the clutch tube.
● Refer to CL-5, "On-Vehicle Inspection and Adjustment" , CL-7, "Air Bleeding Procedure" .
H
Disassembly and Assembly ECS00563

DISASSEMBLY
1. Using a pin punch, remove spring pin, nipple and seal from the
I
cylinder body.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove seat. J
4. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to reduce possibility of the pis-
ton popping out.
K
5. Remove piston assembly and return spring.

SCIA0811E
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 the spring
● Cracked or deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of the cylinder body, sliding surface of piston assembly, and the
piston cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down the push rod
by hand to prevent the piston assembly from popping out.
3. Install seat.
4. Install clevis to the push rod and tighten lock nut to the specified torque.
5. Install seal and nipple to the cylinder body. Using a pin punch, install spring pin.

CL-9
 OPERATING CYLINDER

OPERATING CYLINDER PFP:30620

Removal and Installation ECS00564

SCIA1102E

1. Cylinder body 2. Piston spring 3. Piston cup

4. Piston assembly 5. Push rod 6. Dust cover
7. Air bleeder valve 8. Union bolt 9. Copper washer
10. Clutch hose

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 the 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 the clutch tube.
(Refer to CL-7, "Air Bleeding Procedure" .)
Disassembly and Assembly ECS00565

DISASSEMBLY
● Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside the 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 inner 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 inner surface and rubber grease to the piston cup and piston.
Insert piston assembly and piston spring into the 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 ECS00566

Carefully observe the following steps during clutch tube removal and installation.
● Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area B
with water.
● To fix clutch hose on the bracket, position hose clasp on the
bracket locating embossment and drive the lock plate vertically CL
from above. Be careful not to bend or twist the hose. Do not
scratch or damage the clutch hose.
● Tighten clutch tube flare nut to the specified torque below: D

: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

● Tighten clutch hose union bolt to the specified torque: E

: 16.7 - 19.6 N·m (1.7 - 1.9 kg-m, 13 - 14 ft-lb)

SCIA0326E
CAUTION: F
Do not reuse the copper washer.
● After installation, bleed the clutch tube.
(Refer to CL-7, "Air Bleeding Procedure" .) G

CL-11
 CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISM PFP:30502

Removal and Installation ECS00567

SCIA0328E

REMOVAL
1. Remove manual transaxle from the vehicle.
● Refer to MT-16, "Removal and Installation" .

2. Remove release bearing, holder spring, and withdrawal lever from inside the clutch housing.
3. Remove dust cover.
4. Remove retainer spring from the 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 the 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 ECS00568

—QR engine models—

SCIA0329E

—YD engine models—

SCIA0813E

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-16, "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 (special service tool).
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in) J

● Check clutch cover thrust ring for wear or breakage. If wear or

breakage is found, replace clutch cover assembly.
K
NOTE:
● Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer. SCL466-C
L
● 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 the assembly. M

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-101, "Flywheel Deflection" .
Vehicles with YD engine models:
Refer to EM-220, "Flywheel Deflection" .
AEM100
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 KV30100100
YD engine ST20630000
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
First step:
SCIA0909E

: 10 - 19 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb)

Final step:
QR engine models
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
YD engine models
: 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 21 ft-lb)
4. Install manual transaxle.
● Refer to MT-16, "Removal and Installation" .

CL-16
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Clutch Control System ECS00569

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS0056A

Inner diameter 15.87 mm (5/8 in)

CL
Clutch Operating Cylinder ECS0056B

Inner diameter 19.05 mm (3/4 in)

D
Clutch Disc ECS0056C

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
Thickness of disc assembly with load 7.90 - 8.30 mm (0.3110 - 0.3268 in) with 5,688 N (580 kg, 1,279lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be G
1.0 mm (0.039 in) or less/ 230 mm (9.06 in) dia.
measured
Maximum spline backlash
1.0 mm (0.039 in)
(at outer edge of disc)
H
Clutch Cover ECS0056D

Engine type QR20DE QR25DE YD22DDTi

I
Model 240
Set-load 4,903 N (500 kg, 1,103 lb) 5,884 N (600 kg, 1,323 lb) 6,865 N (700 kg, 1,544 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.457 - 1.535 in) J
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less

Clutch Pedal ECS0056E K

Engine type QR20DE QR25DE YD22DDTi
Clearance between clutch switch thread
0.1 - 1.0 mm (0.004 - 0.039 in) L
end and stopper rubber

CL-17
SERVICE DATA AND SPECIFICATIONS (SDS)

CL-18