Removal of Clutch Assembly Components

Be aware that dust generated by wear of the clutch disc friction linings may contain asbestos, which is harmful to health. Do not blow off dust with compressed air and avoid inhaling it. Do not use petroleum-based solvents to clean clutch components. Use only special brake cleaners or pure methyl alcohol. Place used rags in a tightly sealed container.

PROCEDURE

1. To gain access to the clutch assembly, the transmission is usually removed, leaving the engine in the vehicle. If the engine has already been removed for general or major repair, the condition of the clutch components must be checked without fail. Given the relatively low cost of parts and the considerable labor required to gain access to the clutch assembly, it makes sense to replace the clutch regardless of the condition of its components. The following describes the procedure for removing the clutch without removing the engine from the vehicle.
2. Remove the manual transmission (refer to 5-Speed Manual Transmission (MTM)). Support the engine with a jack, or suspend it from above with a hoist (the latter is preferred). If using a jack, place a wooden block between its head and the oil pan to distribute the load.

The oil pump pickup is located very close to the bottom of the oil pan and can easily be damaged if the pan is deformed.
3. The clutch release fork and release bearing may be left in their original positions in the transmission housing.
4. To prevent the clutch disc from falling out when removing the pressure plate, insert a clutch alignment tool into its hub.

5. Carefully inspect the flywheel and clutch cover surfaces for alignment marks (usually white paint marks in the form of letters X or O). If no marks can be found, make your own mark, clearly indicating the position of the cover relative to the flywheel.

6. Working in a diagonal sequence, loosen the clutch cover-to-flywheel bolts evenly in several steps, fully releasing the diaphragm spring. Firmly supporting the clutch assembly, remove the bolts completely, then separate the cover from the flywheel and remove the entire assembly from the vehicle.