Hyundai Coupes/Sedans 1994-1998 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 13



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Fig. Fig. 1: Clutch disc and pressure plate components-late model



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Fig. Fig. 2: Clutch disc and pressure plate components-early model



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Fig. Fig. 3: The clutch disc and pressure plate are visible after the transaxle is removed



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Fig. Fig. 4: The clutch release bearing and release shaft can be seen at the center of the bell housing



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Fig. Fig. 5: Remove the return clip using pliers....



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Fig. Fig. 6: ....and slide the clutch release bearing off the input shaft



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Fig. Fig. 7: Loosen the pressure plate bolts evenly. When tightening, use a flywheel tool to hold the engine steady



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Fig. Fig. 8: Remove the pressure plate and the clutch disc



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Fig. Fig. 9: Inspect the flywheel for damage. Replace or refinish as necessary



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Fig. Fig. 10: Always clean the flywheel with an evaporative cleaner (brake clean). This prevents contamination of the clutch



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Fig. Fig. 11: The bolt pattern in the flywheel is staggered for easy alignment with the crankshaft flange



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Fig. Fig. 12: Tighten the flywheel bolts evenly to the proper torque. Use a flywheel tool to hold the engine steady



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Fig. Fig. 13: Prior to installing the clutch release bearing, lubricate the clutch release fork with high temperature grease

  1. Remove the transaxle.
  2.  
  3. Insert the forward end of an old transaxle input shaft or a clutch disc guide tool into the splined center of the clutch disc, pressure plate and the pilot bearing in the crankshaft. This will keep the disc from dropping when the pressure plate is removed from the flywheel.
  4.  
  5. Loosen the clutch mounting bolts alternately and diagonally in very small increments, no more than 2 turns at a time, so as to avoid warping the cover flange.
  6.  
  7. Remove the pressure plate and disc.
  8.  
  9. Remove the return clip and the clutch release bearing.
  10.  
  11. On early model clutches, insert tool 09414-24000, or equivalent, in the spring pin and attach the round nut to the end of the tool. While holding the shaft of the special tool, rotate the sleeve with a wrench to force the spring pin out.
  12.  
  13. Remove the clutch release shaft, packings, return spring and the release fork.
  14.  

To install:
  1. Apply a light coating of high temperature grease to the release fork shaft and the clutch release bearing contact surfaces.
  2.  
  3. On early model clutches , align the lock pin holes of the release fork and shaft and drive 2 new spring pins into the holes. Make sure the spring pin slot is at right angles to the centerline of the control shaft.
  4.  
  5. Apply grease into the groove in the release bearing and install bearing into the front bearing retainer in the transaxle. Install the return clip to the release bearing and fork.
  6.  
  7. Make sure the surfaces of the pressure plate and flywheel are wiped clean of grease and lightly sand them with crocus cloth. Lightly grease the clutch disc and transaxle input shaft splines making sure not to allow any grease to contact the clutch disc material or clutch slip may result.
  8.  
  9. Locate the clutch disc on the flywheel with the stamped mark facing outward. Use a clutch disc guide or old input shaft to center the disc on the flywheel and then install the pressure plate over it. Install the bolts and tighten them evenly. Tighten them in increments of 2 turns or less to avoid warping the pressure plate. Torque to 11-15 ft. lbs. (15-21 Nm).
  10.  
  11. Remove the clutch disc centering tool.
  12.  
  13. Install the transaxle.
  14.  
  15. Adjust the clutch free-play.
  16.  

ADJUSTMENTS



Pedal Height and Free-Play

See Figures 14, 15 and 16



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Fig. Fig. 14: Measuring clutch pedal height (A) and clutch pedal clevis pin play (B)



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Fig. Fig. 15: Loosen the stop bolt or clutch pedal position switch and turn the push rod to make the adjustment



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Fig. Fig. 16: Measuring clutch pedal free play (C) and clutch pedal clevis pin play (D)

  1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard). Distance should be 7.0 in. (178 mm).
  2.  
  3. Measure the clutch pedal clevis pin play (measured at the face of the pedal pad). Distance should be 0.04-0.11 in. (1-3 mm).
  4.  
  5. If either measurement is not within specification, adjust as follows:
  6.  
  7. Turn and adjust the stop bolt so that the pedal height is within specification. and secure with the lock nut.
  8.  
  9. When the pedal height is lower than specification, loosen the bolt or clutch pedal position switch and turn the push rod to make the adjustment. Turn the bolt or clutch pedal position switch until it reaches the pedal stopper and then lock with the lock nut.
  10.  

When adjusting clutch pedal height or pedal clevis pin play, be careful not to push the clutch master cylinder rod toward the master cylinder.

  1. Measure the clutch pedal free-play (measured at the face of the pedal pad). Distance should be 0.2-0.5 in. (6-13 mm).
  2.  
  3. Measure the clutch pedal clevis pin play (measured at the face of the pedal pad with the clutch pedal depressed). Distance should be 2.8 in. (90 mm).
  4.  
  5. If the clutch pedal free play and the distance between the clutch pedal and the firewall when the clutch is disengaged are not within specification, it may be the result of air in the hydraulic line or a faulty hydraulic component.
  6.  
  7. Bleed the hydraulic clutch system.
  8.  

 
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