Kia_Sephia_Rio_Spectra_Optima_1998-2006

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 transaxle.
  6.  
  7. Gradually loosen the clutch pressure plate bolts, in a crisscross pattern. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc.
  8.  
  9. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  10.  
  11. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  12.  
  13. Install a flywheel holder to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  14.  
  15. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  16.  
  17. Inspect the release fork for wear or damage and replace as necessary.
  18.  

To install:

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Fig. Structural view of the hydraulic clutch system



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Fig. Exploded view of the clutch assembly



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Fig. Flywheel tightening sequence



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Fig. Pressure plate tightening sequence

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2.  
  3. Install the clutch release bearing on the release fork.
  4.  
  5. Install a new pilot bearing in the flywheel, if removed.
  6.  
  7. Be sure the flywheel mounting surface and the crankshaft or eccentric shaft mounting surfaces are clean. Remove any old sealant from the flywheel bolt hole threads and the flywheel bolts.
  8.  
  9. Install the flywheel.
  10.  
  11. Apply sealant to the flywheel bolt threads and install them hand-tight. Install the flywheel holding tool. Tighten the bolts, in a crisscross pattern, to 71-76 ft. lbs. (96-103 Nm).
  12.  
  13. Apply a small amount of molybdenum grease to the clutch disc splines and install the clutch disc on the flywheel, spring side toward the transaxle. Install a suitable alignment tool in the pilot bearing to position the clutch disc.
  14.  
  15. Install the clutch pressure plate, aligning the dowel holes with the flywheel dowels.
  16.  
  17. Install the pressure plate bolts and gradually tighten, in a crisscross pattern to 20 ft. lbs. (26 Nm). Remove the alignment tool.
  18.  
  19. Install the transaxle.
  20.  

 
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