Kia Sportage 2005-06

Driven Disc & Pressure Plate

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of clutch system components

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the transaxle assembly.
  4.  
  5. Insert the special tool 09411-11000, or equivalent alignment tool, in the clutch disc to prevent the disc from falling.
  6.  
  7. 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. 

  8.  
  9. Remove the release fork shaft and bushing.
  10.  
  11. Apply multipurpose grease to the splines of the disc.  
    WARNING
    When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and shudder. 

  12.  
  13. Install the clutch disc assembly to the flywheel using the alignment.
  14.  
  15. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in the sequence shown. Tighten to 11-16 ft. lbs. (15-22 Nm).

    Click image to see an enlarged view

    Fig. Clutch disc torque sequence

  16.  
  17. Align the bearing (A) to the release fork (B) and then install it to the sleeve of the housing.
    NOTE
    Apply multipurpose grease, CASMOLY L9508, or equivalent, 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. Bearing and release fork grease points

  18.  
  19. Install the release lever to the release fork.
  20.  
  21. Install the transaxle assembly to the engine.
  22.  

 
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