Clutch Cover and Clutch Disc - Removal, Inspection

CLUTCH COVER AND CLUTCH DISC - COMPONENTS

REMOVAL

1. Drain the fluid from the clutch hydraulic system.

Drain the oil from the transmission.

2. Remove the transmission.

3. Insert the special service tool (clutch disc guide 09411-25000) into the clutch disc to prevent the disc from falling.

4. Loosen the clutch cover mounting bolts to the flywheel in a diagonal sequence, in several steps.

5. Loosen the mounting bolts no more than one or two turns at a time to prevent distortion of the clutch cover flange.

Do not clean the clutch disc or the release bearing with solvent.

INSPECTION OF CLUTCH COVER

1. Check the ends of the diaphragm spring fingers for wear and uneven height.

Replace if significant wear or uneven height of the finger ends exceeds the limit.

Limit: 0.5 mm. 2. Check the pressure plate surface for wear, cracks, or discoloration.

3. Check the cover rivets for looseness and replace the clutch cover assembly if necessary.

CLUTCH DISC

1. Check the friction surface of the clutch disc for loose rivets, uneven contact, and damage such as scoring, oil or grease contamination. Replace the clutch disc if any defects are found.

2. Measure the distance from the friction facing surface to the clutch disc rivet heads. Replace the disc if the measured value is less than the limit.

Specified limit: 1.1 mm 3. Check the driven disc damper springs for excessive play and damage.

Replace the disc if 4. Clean the transmission input shaft splines and install the clutch driven disc.

If the clutch driven disc does not move smoothly or has excessive play, replace the clutch disc and/or transmission input shaft.

RELEASE BEARING

The release bearing is filled with special grease.

Do not wash the bearing with solvent or oil.

1. Check the release bearing for binding, damage or noise when rotating. Also check the contact surface of the release bearing with the diaphragm spring for wear.

2. Replace the bearing if the contact surface with the clutch release fork is excessively worn.

CLUTCH RELEASE FORK

If the contact surface of the clutch release fork with the release bearing is excessively worn, replace the clutch release fork assembly.