Engines MR20DE, QR25DE 1. Flywheel; 2. Driven clutch disc; 3. Clutch cover; 4. Drive shaft; A. First pass; B. Final pass.
Attention:
- When removing a manual transmission from a vehicle, always replace the concentric slave cylinder (CSC). To remove the manual transmission, the CSC insert is moved to its original position. Dust on the sliding components of the clutch plate can damage the CSC seal and cause clutch fluid to leak.
- Do not allow lubricant to come into contact with the surface of the clutch driven disc, pressure plate or flywheel.
- When installing, make sure that the lubricant applied to the drive shaft does not get on the clutch driven disc.
- Do not clean the clutch driven disc with solvent.
Removal and installation
Attention. When removing a manual transmission from a vehicle, always replace the concentric slave cylinder (CSC). To remove the manual transmission, the CSC insert is moved to its original position. Dust on the sliding components of the clutch plate can damage the CSC seal and cause clutch fluid to leak.
Removal
1. Remove the manual transmission assembly from the vehicle. See below.
2. Loosen the clutch housing mounting bolts.
3. Remove the clutch cover and clutch plate.
Attention. Do not drop the clutch disc.
Installation
1. Clean the splines of the clutch driven disc and drive shaft by removing grease and dust.
2. Apply the recommended lubricant to the clutch splines and drive shaft.
Attention. Apply lubricant to the indicated points. Otherwise, there may be a knocking noise, incomplete disengagement or damage to the clutch. Excessive grease can cause slipping or shaking, and if contacted with the CSC seal, cause clutch fluid to leak. Wipe off excess grease. Remove any grease that has escaped from the components.
3. Install the driven disc using a suitable clutch centering mandrel.
4. Install the clutch cover. Tighten the clutch housing mounting bolts by hand.
5. Tighten the clutch housing mounting bolts evenly in two passes to the required torque in the order indicated by the numbers in the figure.
6. Install the manual transmission assembly onto the vehicle. See below.
Check after removal
Driven clutch disc
- Measure the runout around the perimeter relative to the central splines of the clutch driven disc.
- If it differs from the norm, replace the clutch driven disc.
Limit runout/diameter of the measured area: See paragraph below. «Technical data and specifications».
- Check the free play in the splines of the clutch driven disc and in the splines of the secondary shaft drive gear around the perimeter of the disc. If it differs from the norm, replace the clutch driven disc.
Maximum allowable free play in splines (on the outer edge of the disk): See paragraph below. «Technical data and specifications».
- Using a caliper, measure the distance «A» from the rivet head to the surface of the friction lining of the disc. If it exceeds the allowable wear, replace the clutch driven disc.
Distance from rivet head to friction lining: See below «Technical data and specifications».
Clutch cover
- Check the unevenness of the tops of the diaphragm spring when the lever is inserted. If it is not normal, adjust the lever height using the aperture key (special tool ST20050240).
Unevenness of the tops of the diaphragm spring: See paragraph below. «Technical data and specifications».
- Check the clutch housing thrust ring for wear or damage. If necessary, replace the clutch housing assembly.
Note:
- A worn thrust ring will make a ticking sound when the rivet is tapped with a hammer.
- A broken thrust ring will make a ringing sound when the housing is shaken.
- If you find traces of burning or discoloration on the contact surface between the clutch housing pressure plate and the driven clutch plate, remove them with emery cloth. If the surface is damaged or deformed, replace the clutch cover.