REMOVAL & INSTALLATION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surface with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.
See Figures 1 through 21
The clutch cover and pressure plate are balanced as an assembly. If replacement of either part becomes necessary--replace both parts (and release bearing) as an assembly.
The flywheel (check torque on flywheel retaining bolts) should be inspected for wear or scoring and resurfaced or replaced as necessary.
Remove the transmission/transaxle from the engine as detailed in this section.
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 that the clutch assembly can be assembled in the same position from which it is removed.
Loosen the bolts in sequence, a turn at a time. Remove the bolts.
Remove the pressure plate and clutch disc.
Remove the release mechanism from the transmission housing. 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.
Inspect the release bearing and replace if necessary. Apply a small amount of grease to the transmission 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.
Install the disc to flywheel, aligning it with a special tool splined dummy shaft.
Install the pressure plate and EVENLY IN A CRISS-CROSS PATTERN torque the bolts to 16-22 ft. lbs.
Remove the dummy shaft.
Replace the transmission/transaxle. Check system for proper operation.
Fig. Fig. 1: Hydraulic clutch control assembly-200SX
Fig. Fig. 2: Clutch release mechanism-240 SX
Fig. Fig. 3: Hydraulic clutch control assembly-240SX
Fig. Fig. 4: Clutch system-1989 Stanza
Fig. Fig. 5: Clutch release mechanism-1989 Stanza
Fig. Fig. 6: Typical clutch alignment tool, note how the splines match the transmission's input shaft
Fig. Fig. 7: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time...
Fig. Fig. 8: ... then carefully removing the clutch and pressure plate assembly from the flywheel
Fig. Fig. 9: Check across the flywheel surface, it should be flat
Fig. Fig. 10: If necessary, lock the flywheel in place and remove the retaining bolts ...
Fig. Fig. 11: ... then remove the flywheel from the crankshaft in order replace it or have it machined
Fig. Fig. 12: Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts
Fig. Fig. 13: Check the pressure plate for excessive wear
Fig. Fig. 14: Be sure that the flywheel surface is clean, before installing the clutch
Fig. Fig. 15: Install a clutch alignment arbor, to align the clutch assembly during installation
Fig. Fig. 16: Clutch plate installed with the arbor in place
Fig. Fig. 17: Clutch plate and pressure plate installed with the alignment arbor in place
Fig. Fig. 18: Pressure plate-to-flywheel bolt holes should align
Fig. Fig. 19: You may want to use a threadlocking compound on the clutch assembly bolts
Fig. Fig. 20: Install the clutch assembly bolts and tighten in steps, using an X pattern
Fig. Fig. 21: Be sure to use a torque wrench to tighten all bolts