REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6 and 7
- Following the procedures outlined earlier in this section, remove the manual transaxle assembly.
- Insert a clutch disc centering tool KV30101000 or equivalent, into the clutch disc hub for support.
- Loosen the pressure plate bolts evenly in reverse order of the tightening sequence, a little at a time to prevent distortion.
- Remove the clutch pressure plate and disc together as an assembly.
- Remove the throwout bearing from the clutch lever, by pulling the bearing retainers outward.
The entire clutch assembly (disc, pressure plate and release bearing) should be replaced or reconditioned at this time. The clutch release mechanism, pilot bearing (if applicable) and flywheel should be carefully inspect prior to reassembly.
- Before continuing, compare the replacement parts with the old components, verifying that they are exactly the same.
- Inspect the flywheel for cracks, discoloration and warpage. Minor imperfections can be corrected by lightly sanding with emery paper. Serious defects require resurfacing or replacement of the flywheel.
- Apply a light coating of a high temperature chassis lubricant to the clutch disc splines, input shaft and pilot bearing. Install the disc and pressure plate. Use a disc centering tool to aid installation. Torque the pressure plate bolts in sequence and in several steps to 16-22 ft. lbs. (20-26 Nm).
- Install the new throwout bearing in the clutch release lever. Remove the clutch disc centering tool.
Install the transaxle into the vehicle. If the mating surfaces will not come together, do not force the units together perform the following steps:
- Remove the transaxle and recheck that the disc is centered.
- Clean dowel pins and alignment holes.
- After the transaxle is installed, connect the clutch cable and check operation before complete reassembly.
- Adjust the clutch pedal as necessary.