REMOVAL & INSTALLATION
See Figures 1 through 16
- Disconnect the negative battery cable.
- Raise and safely support the vehicle.
- Remove the transaxle assembly.
During the removal procedure, do not allow oil or grease to come in contact with the clutch disc facing if the disc is to be reused. Handle the disc with clean rags wrapped around the edges and do not touch the disc facing. Even a small amount of dirt or grease may cause the clutch to grab or slip.
- If the pressure plate is to be reused, paint or scribe alignment marks on the pressure plate and flywheel for assembly reference.
- Install an appropriate locking tool to prevent the flywheel from turning.
- Install a clutch aligning tool to prevent the clutch plate from dropping when the retaining bolts are removed.
- Loosen the 6 pressure plate retaining bolts in an alternate pattern, one turn at a time; this will relieve the pressure plate spring tension evenly and prevent distortion of the pressure plate.
- Remove the pressure plate and clutch disc once the retaining bolts are loosened.
- Inspect all clutch components including the clutch release fork and release bearing, and replace as required.
- Inspect the flywheel for scoring, cracks and heat checks. Resurface or replace the flywheel, as necessary.
- Inspect the pilot bearing for damage. Make sure the bearing turns easily. If replacement is necessary, remove the flywheel and the pilot bearing.
- If necessary, install a new pilot bearing using a suitable installation tool. Use only a driver tool that contacts the bearing outer race. A driver tool that contacts the inner race or the bearing area will damage the bearing.
- If the flywheel was removed, clean the sealant from the flywheel retaining bolts. Coat the bolt threads with a suitable sealer compound.
- Make sure the crankshaft flange and the back of the flywheel are clean. Position the flywheel on the crankshaft and install the 6 retaining bolts. Tighten the bolts to 71-76 ft. lbs. (96-103 Nm).
- Position the clutch disc on the flywheel and install a clutch alignment tool to hold the disc in place.
When installing the clutch disc, make sure the disc dampener springs are facing away from the flywheel. A new disc will be stamped FLYWHEEL to indicate the correct installation position.
- Align the reference marks, if present, and position the pressure plate on the flywheel, then install the retaining bolts. Tighten the bolts evenly, in an alternate pattern, to 13-20 ft. lbs. (18-26 Nm). The bolts must be tightened in this manner to prevent distortion of the pressure plate.
- Remove the clutch alignment tool.
- Clean the clutch disc splines on the input shaft with a dry rag and coat the spline surfaces with a light film of clutch grease.
- Install the transaxle.
- Lower the vehicle.
- Connect the negative battery cable.
- Adjust the clutch pedal free-play.
- Road test the car and check for proper clutch operation.
Clutch Pedal Height
See Figure 17
- Disconnect the clutch cable at the release lever.
- Move the carpet and padding aside so that it will not influence the measurement.
- Measure the distance from the upper center of the pedal to the bulkhead. The pedal height should be 8.075 in. (205mm). If the height is not as specified, continue with the adjustment.
- Inspect the pedal mounting, for damaged, worn or missing parts. Repair as necessary and continue with the adjustments.
The Clutch Pedal Position (CPP) switch also serves as the pedal stop.
- Loosen the CPP switch locknut and thread the switch in or out until the pedal is at the specified height. Tighten the locknut to 10-13 ft. lbs. (14-18 Nm).
- Connect the clutch cable to the release lever and adjust clutch free-play.
- Recheck the pedal height. If connecting the clutch cable affected pedal height, check the cable for binding or damage. Repair as necessary.
See Figures 18 and 19
- Move the clutch pedal back and forth, and measure the amount of travel (free-play).
- The free-play should be 0.35-0.59 in.(9-15mm). If the measurement is not as specified, continue with the adjustments.
- Pull back on the clutch release lever and measure the clearance between the lever and the clutch cable connecting link. Thread the adjuster in or out until the measurement between the connecting link and lever is 0.06-0.10 in. (1.5-2.5mm).
- Check the free-play again and make sure the measurement is as specified. If not, check the clutch release components for damage or binding.
- After the adjustment, measure the clutch disengagement height. It should be a minimum of 2.92 in. (74mm) when disengaged.