Kia Picanto JA Quiz
Clutch System

Clutch Release Fork and Clutch Release Bearing

In this manual: Clutch System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
23steps
~138min
5/5difficulty
Done 0 of 23

Components and Component Location

Components

[Kappa 1.0 MPI/FFV, Kappa 1.2 MPI]
1. Clutch Disc Assembly
2. Clutch Cover Assembly
3. Clutch Release Bearing
4. Clutch Release Lever Assembly		 5. Return Spring
6. Clutch Release Fork
7. Return Clip

[Kappa 1.0 T-GDI]
1. Clutch Release Fork
2. Clutch Cover Assembly		 3. Clutch Disc Assembly
4. Clutch Release Bearing

Repair Procedures

Removal

[Kappa 1.0 MPI/FFV, Kappa 1.2 MPI]
  1. Remove the transaxle assembly. G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle") G 1.2 MPI KAPPA (Refer to Manual Transmission System - "Manual Transmission") F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")
  2. Remove the reamer bolt.
  3. Remove the return clip (A) from the release bearing, then remove the release fork and release bearing.
  4. Remove the transaxle assembly. G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
  5. Remove the clutch release bearing (A).
  6. Pull the clip (A).
  7. Remove the clutch release fork (A).
  8. Remove the boot (A).
[Kappa 1.0 T-GDI]

Installation

[Kappa 1.0 MPI/FFV, Kappa 1.2 MPI]
  1. Apply multi-purpose grease to the release fork assembly.
  2. Apply multi-purpose grease to the groove of the release bearing.

    Lubricant: CASMOLY L9508 (0.4–0.8 g)

  3. Install the release bearing and release fork on the clutch housing.
  4. Install the reamer bolt.
  5. Apply multi-purpose grease to the contact surface of the lever (A).

    Lubricant: CASMOLY L9508 (0.2–0.4 g)

  6. Thoroughly clean the surfaces of the flywheel and pressure plate with fine sandpaper or crocus cloth, and make sure all oil or grease has been removed.
  7. Apply a small amount of multi-purpose grease to the splines of the input shaft (A).

    Lubricant: CASMOLY L9508 (approx. 0.2 g)

  8. Thoroughly clean the surfaces of the flywheel and pressure plate with fine sandpaper or crocus cloth, and make sure all oil or grease has been removed.
  9. Install the transaxle assembly. G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle") G 1.2 MPI KAPPA (Refer to Manual Transmission System - "Manual Transmission") F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")
  10. Install the boot (A).
  11. Install the clip on the clutch release fork.
  12. Apply grease at points A, B, and C.
    Location Quantity (g) Notes
    A 0,3 - 0,5 Release Bearing and Fork
    B 0,5 - 1,0 Release Fork and Pivot Point
    C 0,4 - 0,8 Release Cylinder and Fork

  13. Apply grease to the surface of the clutch release bearing hole on all sides.

    Recommended lubricant: CASMOLY L9508. Quantity: 0.5 - 1.0 g

  14. Install the clutch release fork (B) and clutch release bearing (A).
  15. Install the transaxle assembly. G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
[Kappa 1.0 T-GDI]

Test yourself

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