Kia Forte BD Quiz

Clutch System

In this manual: Clutch System
General Information — 8Maintenance — 32Engine Mechanical System — 47Engine Electrical System — 17Emission Control System — 10Engine Control System/Fuel System — 32Clutch System — 11Manual Transmission — 11DCT (Dual Clutch Transmission) System — 16Drive Shaft and Axle — 8Suspension System — 26Steering — 9Restraints — 11Brake System — 27Body (Interior and Exterior) — 119Body Electrical System — 98Heating, Ventilation, and Air Conditioning — 27
~4min read
1special tools

Service Data

Service Data

Items Specifications
Clutch Operating Method Hydraulic Type
Clutch Cover Type Diaphragm Spring Strap
Clutch Disc Type Single Dry Diaphragm
Facing Diameter
(Outer × Inner)		 Ø235 × Ø155 mm (Ø9.2520 × Ø6.1024 in.)
Thickness [When Free] Ø8.3 ± Ø0.3 (0.3268 ± 0.0118 in.)
Rivet Depth Min. 1.1 mm (0.0433 in.)

Service Standard

Item Specification
Clutch Disc Rivet Depth 0.3 mm (0.0118 in.)

Tightening Torque

Tightening torque

Item N·m kgf·m lbf·ft
Clutch Pedal Mounting Bolt and Nut 16,7 - 25,5 1,7 - 2,6 12,3 - 18,8
Clutch release cylinder mounting bolt 14,7 - 21,6 1,5 - 2,2 10,8 - 15,9
Concentric Slave Cylinder Assembly Mounting Bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Ignition Switch and Clutch Switch Mounting Bolt 2,0 - 5,9 0,2 - 0,6 1,4 - 4,3
Clutch Tube Bracket Mounting Bolt 7,8 - 9,8 0,8 - 1,0 5,8 - 7,2
Clutch release cylinder bleeder screw 7,8 - 13,7 0,8 - 1,4 5,8 - 10,1
Clutch Release Cylinder Assembly Mounting Nut 14,7 - 21,6 1,5 - 2,2 10,8 - 15,9
Concentric Slave Cylinder Assembly Mounting Bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Clutch Housing Bolt (Gasoline 1.6) 24,5 - 35,3 2,5 - 3,6 18,1 - 26,0
Clutch Cover Mounting Bolt (Gasoline 2.0) 11,8 - 14,7 1,2 - 1,5 8,7 - 10,8

Lubricants

Lubricants

Items Specified Lubricants Quantity
Clutch Release Cylinder Assembly DOT 3 or DOT 4 brake fluid As Required
Clutch pedal shaft and bushing Chassis grease SAE J310a, NLGI No. 1 0.2 - 2.0 g
Input shaft spline CASMOLIA L9508 0.2 g
Release Bearing and Fork 0.3 - 0.5 g
Release Fork and Pivot Point 0.5 - 1.0 g
Release Cylinder and Fork 0.4 - 0.8 g
Clutch Release Bearing and Clutch Housing 0.5 - 1.0 g

Special Service Tools

Special Service Tools

Tool Name/Number Illustration Description
Clutch Disc Guide
09411-1P000
Clutch disc installation

Troubleshooting

Troubleshooting

Symptom of Malfunction Suspected Area Remedy
Clutch Slipping

  • Vehicle does not respond to engine speed when accelerating

  • Insufficient vehicle speed

  • Lack of power when driving uphill

 Insufficient clutch pedal free play Adjust
Clogged hydraulic system Repair or replace parts
Excessive wear of clutch disc facing Replace
Glazed clutch disc surface or oil on surface Replace
Pressure plate or flywheel damaged Replace
Weak or broken diaphragm spring Replace
Hard shifting (gear noise when shifting) Excessive clutch pedal free play Adjust
Hydraulic system fluid leakage, air intrusion, or clogging Repair or replace parts
Unusual wear or corrosion of clutch disc spline Replace
Excessive vibration (deformation) of clutch disc Replace
Clutch noisy When clutch is not in use Insufficient clutch pedal stroke Adjust
Excessive wear of clutch disc facing Replace
Noise after clutch is disengaged Unusual wear and/or damage of release bearing Replace
Noise when clutch is disengaged Insufficient grease on bearing bushing sliding surface Repair
Improperly installed clutch assembly or bearing Repair
Noise when vehicle suddenly rolls with clutch partially engaged Damaged guide bushing Replace
Hard clutch pedal effort Insufficient lubrication of clutch pedal Repair
Insufficient lubrication of clutch disc spline Repair
Insufficient lubrication of clutch release lever shaft Repair
Shifting is difficult or gears do not engage Excessive clutch pedal free play Adjust pedal free play
Clutch release cylinder malfunction Repair release cylinder
Clutch disc misaligned, runout excessive, or facing damaged Inspect clutch disc
Input shaft or clutch disc splines contaminated or burnt Repair as necessary
Clutch pressure disc malfunction Replace clutch cover
Clutch slips Insufficient clutch pedal free play Adjust pedal free play
Clogged hydraulic system Repair or replace parts
Clutch disc facing oily or worn Inspect clutch disc
Faulty pressure plate Replace clutch cover
Release fork binding Inspect release fork
Clutch grabs / chatters Clutch disc facing oily or worn Inspect clutch disc
Pressure plate malfunction Replace clutch cover
Clutch diaphragm spring bent Replace clutch cover
Torsion spring worn or broken Replace clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Clutch pedal bushing damaged Replace the clutch pedal bushing
Loose part inside the housing Repair as necessary
Worn or dirty clutch release bearing Replace the clutch release bearing
Sticking clutch release fork or linkage Repair as necessary

Test yourself

A quick Kia Forte BD quiz: every answer comes with an explanation and a link to the manual page.