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Clutch Replacement

Special Tools Required

Stop collar
 070AF-SMGC150

Ring gear holder
 07LAB-PV00100

Pressure plate compressor
 070AE-0010100

Center shaft
 070AF-SMGC140

Bearing remover shaft 15
 07936-KC10100

Bearing remover head 15
 07936-KC10200

Driver handle, 15 x 135L
 07749-0010000

Bearing driver attachment, 28 x 30 mm
 07946-1870100
Engine Side
You must use the pressure plate compressor, the center shaft, and the stop collar required to remove and install the clutch pressure plate or you will damage it.
Pressure Plate Inspection and Removal
  1. Check the evenness of the height of the diaphragm spring fingers using the center shaft, the stop collar (A), and a feeler gauge (B). If the height difference is more than the service limit, replace the pressure plate and clutch disc as a set.
    Standard (New):
    0.8 mm (0.03 in.) max.
    Service Limit:
    1.0 mm (0.04 in.)


  1. Install the center shaft (A), the stop collar (B), the pressure plate compressor (C), and the ring gear holder (D).
  1. Turn the center screw (E) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.

  1. Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.
  1. Turn the center screw (B) on the pressure plate compressor counterclockwise by hand to release the pressure, then install two pressure plate mounting bolts by finger-tight to hold the pressure plate (C).
  1. Remove the stop collar, the pressure plate compressor, then remove the finger-tightened bolts and the pressure plate.

  1. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.

  1. Inspect the pressure plate surface (A) for wear, cracks, and burning.

  1. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the most measurement difference is more than the service limit, replace the pressure plate and clutch disc as a set.
    Standard (New):
    0.03 mm (0.001 in.) max.
    Service Limit:
    0.15 mm (0.006 in.)


Clutch Disc Inspection and Removal
  1. Remove the clutch disc (A) and clutch center shaft (B).
  1. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc and the pressure plate as a set. If the clutch disc is oil soaked, find and repair the source of the oil leak.

  1. Measure clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc and pressure plate as a set.
    Standard (New):
    7.6−8.0 mm (0.299−0.315 in.)
    Service Limit:
    6.0 mm (0.236 in.)


  1. Measure the rivet depths from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement is less than the service limit, replace the clutch disc and pressure plate as a set.
    Standard (New):
    1.1 mm (0.043 in.) min.
    Service Limit:
    0.3 mm (0.012 in.)


Flywheel Inspection
  1. Remove the ring gear holder.
  1. Inspect the ring gear teeth for wear and damage.
  1. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning.
  1. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with pushing against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within the standard, replace the flywheel, and recheck the runout. Go to Step 20 .
    Standard (New):
    0.05 mm (0.002 in.) max.


Flywheel Replacement
  1. Install the ring gear holder.
  1. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder.
  1. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.

  1. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.

Pilot Bearing Inspection
  1. Inspect the crankshaft pilot bearing for wear and damage.
  1. Inspect the inside surface of the crankshaft pilot bearing with your finger. If the crankshaft pilot bearing is not smooth, replace it; go to Step 26 .

Pilot Bearing Replacement
  1. Remove the crankshaft pilot bearing (A) using the bearing remover shaft (B), bearing remover head (C), and the sliding hammer weight (D).

  1. Install the new pilot bearing (A) into the crankshaft using the 15 x 135L driver handle (B) and 28 x 30 mm bearing driver attachment (C). Apply a light coat of molybdenum grease to the bearing surface.

Clutch Disc and Pressure Plate Installation
NOTE: The clutch disc and pressure plate are a matched set and must be replaced together.
  1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
  1. Apply a light coat of molybdenum grease to the crankshaft pilot bearing (A).
  1. Apply molybdenum grease to the splines (B) of the clutch disc (C), then install the clutch disc using the clutch center shaft (D).

  1. Align point marks (A) across the pressure plate (B) and flywheel (C).
  1. Install the pressure plate and the mounting bolts (D) by finger-tight.

  1. Install the stop collar (A) and the pressure plate compressor (B).
  1. Turn the center screw (C) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.
  1. Be careful not to damage the pressure plate (D). Tighten (180 degrees apart) the pressure plate mounting bolts (E) in the pattern as shown in several steps.
    Specified Torque:
    25 N·m (2.6 kgf·m, 19 lbf·ft)

  1. Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure. Remove the pressure plate compressor, the stop collar, the center shaft, and the ring gear holder.
  1. Make sure the diaphragm spring fingers are all the same height.
  1. Do the release bearing inspection, and replace if it necessary.

Transmission Side
Release Bearing Removal
  1. Remove the release fork boot (A) from the clutch housing (B).
  1. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D). Remove the release bearing (E).

Release Bearing Inspection
  1. Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace the release bearing.
    NOTE: The release bearing is packed with grease. Do not wash it in solvent.

Release Bearing Installation
  1. Apply molybdenum grease to the release fork (A), release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas, then set the release fork set spring (E).
    NOTE: Replace the release fork bolt if necessary.

  1. With the release fork (A) slide between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole (C) in the clutch housing.
  1. Align the detent (D) of the release fork with the release fork bolt (E), then press the detent of the release fork over the release fork bolt squarely.
  1. Install the release fork boot (F). Make sure the boot seals around the release fork and clutch housing.

  1. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Wipe off any excess grease.