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CL-1
CLUTCH
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTIONCL
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B
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CLUTCH
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
CLUTCH PEDAL ........................................................ 6
On-Vehicle Inspection and Adjustment .................... 6
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ......................................................... 10
OPERATING CYLINDER ...........................................11
Components ............................................................ 11
Removal and Installation ......................................... 11REMOVAL ........................................................... 11
INSTALLATION ................................................... 12
Disassembly and Assembly .................................... 12
DISASSEMBLY ................................................... 12
INSPECTION AFTER DISASSEMBLY ................ 12
ASSEMBLY ......................................................... 12
CLUTCH PIPING ....................................................... 13
Removal and Installation ........................................ 13
CLUTCH RELEASE MECHANISM ........................... 14
Removal and Installation ........................................ 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 15
INSTALLATION ................................................... 15
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 17
Removal and Installation ........................................ 17
COMPONENTS ................................................... 17
REMOVAL ........................................................... 17
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 20
Clutch Control System ............................................ 20
Clutch Master Cylinder ........................................... 20
Clutch Operating Cylinder ...................................... 20
Clutch Disc ............................................................. 20
Clutch Cover ........................................................... 20
Clutch Pedal ........................................................... 20
Page 866 of 3171
CL-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
ServiceNoticeorPrecautionsECS00ICC
lRecommended clutch fluid is brake fluid “DOT 3” or “DOT 4”. Refer toMA-14, "RECOMMENDED FLUIDS
AND LUBRICANTS".
lDo not reuse drained clutch fluid.
lBe careful not to splash clutch fluid on painted areas.
lUse a flare nut wrench, when removing and installing clutch pip-
ing.
lUse new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
lDo not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.
SBR820BA
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PREPARATION
CL-3
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PREPARATIONPFP:00002
Special Service ToolsECS00ICD
Commercial Service ToolsECS00ICE
Tool number
Tool nameDescription
KV30101400
Drift
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.Installing release bearing
ST20050240
Diaphragm adjusting wrenchAdjusting unevenness of diaphragm spring of
clutch cover
KV30100100
Clutch aligning bar
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.Installing clutch disc
ZZA0838D
ZZA0508D
ZZA1178D
Tool nameDescription
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Removing and installing master cylinder
spring pin
GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)Removing and installing clutch piping
ZZA0515D
S-NT406
Page 868 of 3171
CL-4
PREPARATION
Flare nut torque wrench
a: 14 mm (0.55 in)Removing and installing clutch piping (For
LHD models)
PullerRemoving release bearing Tool nameDescription
S-NT406
NT077
Page 869 of 3171

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CL-5
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS00ICF
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-6CL-8CL-9CL-11EM-106CL-14CL-17EM-134
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 4 5 5 5 5 5 5 6 6 7
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CL-6
CLUTCH PEDAL
CLUTCH PEDAL
PFP:46540
On-Vehicle Inspection and AdjustmentECS00ICG
1. Make sure that clevis pin floats freely in the bore of clutch pedal.
It should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten lock nut.
c. Make sure that clevis pin floats in the bore of clutch pedal. It
should not be bound by clutch pedal.
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
the pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move clutch pedal up and down to determine if it moves freely.
b. If any sticking is found, replace related parts (clutch pedal bracket, assist spring, bushing etc.) Re-assem-
ble clutch pedal and again make sure that clevis pin floats freely in the bore of clutch pedal.
3. Adjust clearance “C” while depressing clutch pedal fully. (With
clutch interlock switch)
4. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding is found, repair or replace related parts
as necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer toCL-8, "
Air Bleeding Procedure".
NOTE:
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all the air from the system.Clearance “C” : 0.1 - 1.0 mm (0.004 - 0.039 in)
PCIB0907E
SCL800
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CLUTCH PEDAL
CL-7
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Removal and InstallationECS00ICH
COMPONENTS
REMOVAL
1. Disconnect clutch interlock switch and ASCD clutch switch (with ASCD) harness connectors.
2. Remove snap pin and clevis pin from clevis of clutch master cylinder.
3. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
INSPECTION AFTER REMOVAL
lCheck clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
lCheck assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
Installation is the reverse order of removal.
NOTE:
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.
1. Clutch pedal assembly 2. Clevis pin 3. Bushing
4. Stopper rubber 5. Pedal stopper bolt (Without ASCD) 6. ASCD clutch switch (With ASCD)
7. Pedal pad 8. Stopper rubber 9. Snap pin
10. Clutch interlock switch 11. Bushing 12. Assist spring
PCIB1387E
Page 872 of 3171

CL-8
CLUTCH FLUID
CLUTCH FLUID
PFP:00017
Air Bleeding ProcedureECS00ICI
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
lMonitor clutch fluid level in reservoir tank to make sure it
does not empty.
lKeep painted surface on the body or other parts free of
clutch fluid. If it spills, wipe up immediately and wash the
affected area with water.
lFor RHD models: Bleed air for operating cylinder.
lFor LHD models: Bleed air for clutch connector first, and then for
operating cylinder.
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer toCL-11,
"Components"andCL-13, "Removal and Installation".
PCIB1601E
PCIB1390E