AutoZone 1998 Pontiac Trans Am 5.7L SFI 8cyl | Repair Guides | Drive Train | Clutch | Clutch Assembly | AutoZone.com

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    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

    Clutch Assembly

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    CAUTION
    The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

    REMOVAL & INSTALLATION



    See Figures 1 through 13

    1. Disconnect the negative battery cable for safety.
    2.  
    3. Remove the transmission from the vehicle.
    4.  
    5. Hold the flywheel from turning using a large prytool or a special flywheel holding tool which locks the flywheel teeth. With the flywheel held stationary, loosen and remove the pressure plate mounting bolts.
    6.  


    WARNING
    In case you plan on using the pressure plate again, be careful to loosen the bolts gradually, one turn at a time, in a star pattern. This gradual release of the pressure plate spring tension helps to prevent possible warping and damage to the plate and spring assembly.



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    Fig. Fig. 1: Remove the transmission assembly for access to the clutch disc and pressure plate



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    Fig. Fig. 2: Loosen the pressure plate bolts gradually, using several passes of a crisscross sequence ...



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    Fig. Fig. 3: ... then remove the pressure plate along with the clutch disc beneath it



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    Fig. Fig. 4: Use a dial indicator to check the flywheel for excessive runout



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    Fig. Fig. 5: A depth gauge can be used to determine clutch disc wear-measure the depth of the rivet head below the friction surface



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    Fig. Fig. 6: A light glaze can be broken using 120-200 grit sandpaper (1)



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    Fig. Fig. 7: Remove the throwout bearing for cleaning and inspection-but DO NOT submerge a sealed bearing in solvent

    1. Remove the pressure plate and the clutch disc from the flywheel.
    2.  
    3. Inspect the flywheel for wear and/or scoring and machine or replace, as necessary. Check the flywheel for excessive runout using a dial indicator; if runout exceeds 0.0078 in. (0.2mm) the flywheel should be machined or replaced.
    4.  
    5. Inspect the clutch disc and pressure plate for wear or damage. Check the depth of the rivet heads on the clutch disc. Standard depth is 0.05 in (1.2mm) for the Samurai or 0.06 in. (1.6mm) for other models. The wear limit is 0.02 in. (0.5mm) for all models. Any clutch disc showing wear equal to or greater than the wear limit should be replaced.
    6.  
    7. Check the clutch disc, pressure plate and flywheel for light burnt or glazed surfaces. A glazed component will have a glass-like surface. If found, break the glass-like finish of light glazing using 120-200 grit sandpaper.
    8.  
    9. Clean and inspect the clutch release bearing and the input shaft. Many of the late-model trucks covered by this guide utilize a sealed release bearing. DO NOT submerge a sealed bearing in or soak it with solvent.
    10.  

    The clutch release bearing is a relatively inexpensive part, that performs a very important function. ALWAYS replace the bearing when a new disc and pressure plate is installed. For that matter, it is not a bad idea to replace it even when other components are being reused.

    1. Make sure that the pressure plate retaining bolts and the bolt holes in the flywheel are clean and free of grease or oil to assure proper fastening during installation.
    2.  

    To install:
    1. Apply a high temperature lithium grease to the thrust surfaces on the throwout bearing and input shaft. Be careful not to apply too much grease which could come off and contaminate the surfaces of the clutch disc.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 8: Clean the components in the bell housing to determine if any require replacement and to prepare them for fresh grease1. Throwout pivot 2. Throwout arm 3. Throwout bearing 4. Input shaft



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    Fig. Fig. 9: Lithium grease application areas-Samurai throwout bearing



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    Fig. Fig. 10: Be sure to coat all thrust surfaces of the throwout bearing and input shaft with a light application of high temperature lithium grease



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    Fig. Fig. 11: When installing the throwout bearing, be sure to locate the retaining pin on the throwout arm within the slot on the bearing case



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    Fig. Fig. 12: Position the clutch disc to the flywheel using a clutch alignment tool ...



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    Fig. Fig. 13: ... then place the pressure plate assembly over top and secure using the retaining bolts once both components are centered

    1. Make sure the clutch disc, pressure plate and flywheel surfaces are clean and free of all grease, oil or other possible contaminants.
    2.  
    3. Using a clutch alignment arbor (preferably the exact one with the proper sized pilot and proper splines), position and hold the clutch disc against the flywheel.
    4.  

    There are several inexpensive clutch alignment tools on the market. One company even makes small plastic replicas of the input shaft. These plastic alignment tools are well designed and work perfectly for most applications.

    1. Install the pressure plate over the disc, flywheel and alignment arbor assembly, then carefully finger-tighten the bolts.
    2.  
    3. Check to make sure that the clutch disc is properly aligned to the pressure plate and flywheel. To do this, first look down the length of the alignment arbor and make sure it seems perfectly straight. Next, grasp the end of the arbor and withdraw it gently (note the pressure plate bolts must have been tightened sufficiently to hold the clutch plate at this stage or it will fall out of alignment the second that the arbor is removed). If the clutch disc is properly aligned, the arbor will slide smoothly out from the flywheel pilot and the clutch splines. The arbor should also insert back into both without any hesitation.
    4.  
    5. Once you are satisfied that the disc is properly aligned, tighten the pressure plate bolts and evenly using multiple passes of a star pattern until all are tightened to 159-248 inch lbs. (18-28 Nm).
    6.  
    7. Remove the clutch disc alignment tool.
    8.  
    9. Install the transmission.
    10.  
    11. Check and adjust the clutch, as necessary.
    12.  
    13. Connect the negative battery cable.
    14.  

    ADJUSTMENTS



    Clutch Pedal Height

    See Figures 14, 15 and 16

    The clutch pedal height should not be a periodic adjustment, but may be checked from time-to-time. More importantly, it should be checked after components of the mechanical clutch system have been replaced.



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    Fig. Fig. 14: The clutch pedal height is adjusted using the adjust bolt and locknut-Samurai models shown



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    Fig. Fig. 15: The pedal height on 1990 and later Samurai models is determined by comparing fully depressed to released positions



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    Fig. Fig. 16: On Sidekick, Tracker and X-90 models the clutch pedal height should be 0.2 in. (5mm) above the brake pedal height (measured as dimension "a")

    The proper height varies slightly from model-to-model:



    Samurai Models through 1989-clutch pedal height should be equal with the brake pedal
     
    Samurai Models 1990 and later-clutch pedal height is determined by total pedal travel. From fully depressed-to-released the pedal should travel 5.83-6.06 in. (148-154 mm).
     
    Sidekick, Tracker and X-90 models-clutch pedal height should be 0.2 in. (5mm) above the brake pedal height
     

    If adjustment is necessary, loosen the locknut and turn the adjusting bolt until the appropriate height is reached. Once set, keep the bolt from turning and tighten the locknut to secure the adjustment.

    Clutch Pedal Free-Play

    See Figures 17, 18, 19 and 20



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    Fig. Fig. 17: Clutch cable routing-Samurai shown, other models are similar

    Unlike pedal height, which should not change because of wear, the clutch pedal free-play will tend to change as the clutch disc wears. The pedal free-play should therefore be checked from time-to-time in order to assure proper clutch operation.

    To check pedal free-play depress the clutch pedal, but stop and hold the moment that clutch resistance is felt. Measure the distance that the pedal traveled from the point it was released to the point where resistance was first felt. The resulting measurement is free-play.

    Proper clutch free-play should be:



    Samurai Models-0.8-1.2 in. (20-30mm).
     
    Sidekick, Tracker and X-90 Models-0.6-1.1 in. (15-25mm).
     



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    Fig. Fig. 18: On the Samurai, clutch pedal free-play is adjusted at the cable joint nut



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    Fig. Fig. 19: Clutch pedal free-play is the distance the pedal moves before resistance is felt (dimension "b")



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    Fig. Fig. 20: For the Sidekick, Tracker and X-90, pedal free-play is adjusted at the joint nut (2), while keeping the outer cable nuts (3) tightened around the center cable thread portion-when finished the release arm free travel ("c") should be 0.02-0.06 in. (0.5-1.5mm).

    1. If the free-play must be adjusted on Samurai models, turn the clutch cable outer nut until the proper measurement is obtained at the pedal. Once adjustment is completed, measure the amount of clutch cable that protrudes past the joint nut, it must be at least 0.196 in. (5mm).
    2.  
    3. If the free-play must be adjusted on Sidekick, Tracker or X-90 models, turn the joint nut (2) located at the transmission end of the clutch cable in or out, as necessary to achieve the proper play. But, make sure that the outer cable nuts (3) are tightened around the center of the outer cable thread portion. Once the correct pedal free-play is obtained, check the free-play on the release arm itself (c), it should be 0.02-0.06 in. (0.5-1.5mm).
    4.  
    5. On all models, once you are finished, check pedal adjustment and clutch function with the engine running.
    6.  

     
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