Hyundai Santa Fe 2001-05

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the transmission assembly.
  6.  
  7. If the pressure plate is attached to the flywheel, remove the release bearing using snap-ring pliers as follows:
    1. Insert the snap-ring pliers under the wave washer and place it in the center of the snap-ring
    2.  
    3. Spread the snap-ring by pushing down on the bearing assembly.
    4.  
    5. Once the snap-ring is fully expanded, remove the release bearing
    6.  

  8.  
  9. Install a clutch disc alignment tool.
  10.  
  11. Remove pressure plate retaining bolts using a star pattern in several passes.
  12.  
  13. Remove the pressure plate with clutch disc.
  14.  

To install:

  1. Apply multi-purpose grease to clutch splines.
  2.  
  3. Install or connect the following:

    Clutch plate to the flywheel
     
    Pressure plate and cover. Do not torque the bolts at this time.
     

  4.  
  5. Align the bearing to the release fork and install it until it is fully engaged.
  6.  
  7. Torque the pressure plate bolts using a star pattern torque sequence to 11-16 ft. lbs. (15-22 Nm) on models with a single mass flywheel or 14-19 ft. lbs. (20-27 Nm) on models with a dual mass flywheel.
  8.  
  9. Install transmission.
  10.  
  11. Connect the negative battery cable.
  12.  

  1. Remove the transaxle assembly.
  2.  
  3. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.

    Click image to see an enlarged view

    Fig. Special tool placement diagram

  4.  
  5. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.
    NOTE
    Do not clean the clutch disc or the release bearing with cleaning solvent.



    Click image to see an enlarged view

    Fig. Clutch disc

  6.  
  7. Remove clutch cover assembly and then driven disc and pressure plate.
  8.  

To install:


CAUTION
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.



Click image to see an enlarged view

Fig. Clutch grease application

  1. Install the driven disc and pressure plate in to the clutch cover assembly.
  2.  
  3. Install the clutch disc assembly to the flywheel using the special tool (09411-11000).
  4.  
  5. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.
  6.  
  7. Tightening torque: Clutch cover bolt = 11-16 ft. lbs. (15-22 Nm).

    Click image to see an enlarged view

    Fig. Clutch cover

  8.  
  9. Align the bearing (A) to the release fork (B) and then install it to the sleeve of the housing.
    CAUTION
    Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve, contact point of the release fork (B) and the bushing inner surface (C).



    Click image to see an enlarged view

    Fig. Release fork grease application

  10.  
  11. Install the release lever to the release fork.

    Click image to see an enlarged view

    Fig. Release lever installation diagram

  12.  
  13. Install the transaxle assembly to the engine.
    CAUTION
    If the transaxle assembly is installed to the engine without performing this step, the release bearing can be separated, as the release fork rotates freely.

  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the transmission assembly.
  6.  
  7. If the pressure plate is attached to the flywheel, remove the release bearing using snap-ring pliers as follows:
    1. Insert the snap-ring pliers under the wave washer and place it in the center of the snap-ring
    2.  
    3. Spread the snap-ring by pushing down on the bearing assembly.
    4.  
    5. Once the snap-ring is fully expanded, remove the release bearing
    6.  

  8.  
  9. Install a clutch disc alignment tool.
  10.  
  11. Remove pressure plate retaining bolts using a star pattern in several passes.
  12.  
  13. Remove the pressure plate with clutch disc.
  14.  

To install:

  1. Apply multi-purpose grease to clutch splines.
  2.  
  3. Install or connect the following:

    Clutch plate to the flywheel
     
    Pressure plate and cover. Do not torque the bolts at this time.
     

  4.  
  5. Align the bearing to the release fork and install it until it is fully engaged.
  6.  
  7. Torque the pressure plate bolts using a star pattern torque sequence to 11-16 ft. lbs. (15-22 Nm) on models with a single mass flywheel or 14-19 ft. lbs. (20-27 Nm) on models with a dual mass flywheel.
  8.  
  9. Install transmission.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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