I30 1996-1997

Driven Disc & Pressure Plate

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Removal & Installation



  1. Remove the battery and battery bracket.
  2.  
  3. Remove the air cleaner and the air flow meter.
  4.  
  5. Raise and safely support the vehicle so there is clearance to remove the transaxle from underneath. Securely support the engine via the oil pan using a cushioning wooden block and jack.
  6.  
  7. Drain the fluid from the transaxle.
  8.  
  9. Remove the transaxle from the engine and lower to the floor.
  10.  
  11. Insert a clutch aligning bar or similar tool all the way into the clutch disc hub. This must be done so as to support the weight of the clutch disc during removal. Mark the clutch assembly-to-flywheel relationship with paint or a center punch so the clutch assembly can be assembled in the same position from which it is removed.
  12.  
  13. Loosen the bolts in reverse order of tightening sequence, a turn at a time. Remove the bolts.
  14.  
  15. Remove the pressure plate and clutch disc.
  16.  
  17. Remove the release mechanism from the transaxle housing.
  18.  
  19. Inspect the pressure plate for wear, scoring, etc., and resurface or replace, as necessary.
  20.  
  21. Measure the thickness of the clutch plate lining to the rivet heads; if the it is worn to a minimum of 0.012 in. (0.3mm), replace the clutch plate.
  22.  
  23. Inspect the release bearing and replace as necessary.
  24.  
  25. Using a dial indicator, mount it to the engine and inspect the flywheel run-out; if the run-out exceeds 0.0059 in. (0.15mm), replace it.
  26.  

To install:

  1. Apply a small amount of grease to the transaxle input shaft splines. Install the disc on the splines and slide back and forth a few times. Remove the disc and remove excess grease on hub. Be sure no grease contacts the disc or pressure plate.
  2.  
  3. Apply lithium based molybdenum disulfide grease to the bearing sleeve inside groove, the contact point of the withdrawal lever and bearing sleeve, the contact surface of the lever ball pin and lever.
  4.  
  5. Install the release mechanism and release bearing.
  6.  
  7. Install the pressure plate and clutch disc, aligning it with a splined dummy shaft tool KV301010000 or equivalent.
  8.  
  9. Torque the pressure plate bolts in sequence to 25-33 ft. lbs. (34-44 Nm).

    Click image to see an enlarged view

    Fig. Pressure plate bolt tightening sequence-I30 models

  10.  
  11. Remove the dummy shaft.
  12.  
  13. Install the transaxle in the correct position. Torque the transaxle-to-engine bolts.
  14.  
  15. Connect the rear and LH mounts.
  16.  
  17. Connect the speedometer cable.
  18.  
  19. Connect the electrical harness connector.
  20.  
  21. Install the clutch release cylinder.
  22.  
  23. Install the starter assembly.
  24.  
  25. Securely support the transaxle and install the driveshafts.
  26.  
  27. Refill the transaxle with the required amount of approved fluid.
  28.  
  29. Install the air flow meter and the air cleaner.
  30.  
  31. Install the battery and battery bracket.
  32.  
  33. Road test the vehicle for proper shift operation.
  34.  

 
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