CHAPTER 23

1. CHAPTER 23 The Clutch System

2. Checking and Adjusting a Mechanical Clutch 23-1 • Following the specified procedure, inspect the clutch linkage parts for damaged, worn, bent, or missing components. Look for signs of binding, looseness, and excessive wear. Start with the clutch pedal assembly and inspect all components under the dash. Operate the clutch pedal while you are inspecting the components to observe looseness or binding.

3. Checking and Adjusting a Mechanical Clutch 23-1 • Check the clutch linkage components under the hood for the same signs of wear or damage as the components under the dash.

4. Checking and Adjusting a Mechanical Clutch 23-1 • Measure the clutch pedal height. Compare your reading to the specifications and determine any necessary actions to correct any fault.

5. Checking and Adjusting a Mechanical Clutch 23-1 • Measure the clutch pedal free-play. Perform any adjustments as necessary, following the manufacturer's procedure.

6. Checking and Adjusting a Hydraulic Clutch 23-2 • Inspect the clutch master cylinder for correct fluid level and test the quality of the fluid. Inspect all line connections to the master cylinder.

7. Checking and Adjusting a Hydraulic Clutch 23-2 • Check that all hydraulic lines are not kinked or leaking at their connections. This will require that the system be repaired and bled of any air. Check all rubber hoses for dry rot, bulges, or leaks. Make sure all hydraulic components are secure in their mountings.

8. Checking and Adjusting a Hydraulic Clutch 23-2 • Check the boot on the slave cylinder for seepage, which may indicate a leaking slave cylinder piston seal.

9. Checking and Adjusting a Hydraulic Clutch 23-2 • Check clutch pedal height. Measure clutch pedal free-play using a tape measure. Compare your readings to the specifications and determine any necessary actions to correct any fault.

10. Bleeding/Flushing Hydraulic Clutch System Using the Gravity Method 23-3 • If the fluid needs to be flushed, use a suction gun or old anti-freeze tester to suck the fluid out of the clutch master cylinder reservoir. Fill it with the specified fluid.

11. Bleeding/Flushing Hydraulic Clutch System Using the Gravity Method 23-3 • Open the bleeder screw on the slave cylinder. Allow air and fluid to drain from the system into a container.

12. Bleeding/Flushing Hydraulic Clutch System Using the Gravity Method 23-3 • Keep the master cylinder filled. Once all air and old fluid are removed, close the bleeder screw and operate the clutch pedal to check for normal operation. After bleeding the clutch hydraulic system, fill the master cylinder to the correct level with the specified type of brake fluid.

13. Bleeding/Flushing Hydraulic Clutch System Using the Manual Method 23-4 • Remove all old fluid from the reservoir. Fill it with the specified fluid. Have an assistant depress the clutch pedal slowly.

14. Bleeding/Flushing Hydraulic Clutch System Using the Manual Method 23-4 • Open the bleeder valve on the slave cylinder and let fluid run out into a container. When all of the fluid stops flowing, close the bleeder valve and slowly release the pedal. Repeat this process until all air and old fluid are removed from the system. After bleeding the clutch hydraulic system, check for correct pedal feel, and fill the master cylinder to the correct level with the specified type of brake fluid.

15. Bleeding Hydraulic Clutch System Using the Pressure Method 23-5 • Hook up the pressure or vacuum bleeding tool to the vehicle with the correct adapters.

16. Bleeding Hydraulic Clutch System Using the Pressure Method 23-5 • Apply pressure or vacuum to the system.

17. Bleeding Hydraulic Clutch System Using the Pressure Method 23-5 • Open the bleeder screw and allow the fluid and air to be purged from the system. Repeat this process as necessary. After bleeding, check for correct pedal feel, and fill the clutch master cylinder to the correct level with the specified type of brake fluid.

18. Removing and Reinstalling a Transmission/Transaxle 23-6 • Research the procedures and specifications. Ensure that bolts, clips, and fasteners are kept in containers. Make sure the vehicle is secure on the lift. If necessary, drain the transmission fluid to avoid a spill on the floor that may cause a safety hazard.

19. Removing and Reinstalling a Transmission/Transaxle 23-6 • Disconnect the drive shaft or axles and secure them from hanging. Disconnect all wires, tubes, and hoses that may be present and inspect for damage. Disconnect the clutch and shifter linkage and inspect for wear or damage. Secure the transmission with a transmission jack and remove any transmission mounts.

20. Removing and Reinstalling a Transmission/Transaxle 23-6 • Following the specified procedure for the specific type of transmission/transaxle, remove the transmission/transaxle from the vehicle. At this time, you may want to overhaul the transmission/ transaxle or perform other tasks such as inspecting and replacing the clutch assembly or replacing the rear crankshaft main seal.

21. Removing and Reinstalling a Transmission/Transaxle 23-6 • Prepare the transmission to be reinstalled. Ensure that the release (throw-out) bearing and clutch fork are properly installed and the clutch disc is centered in the pressure plate. If specified, lubricate the pilot bushing/bearing.

22. Removing and Reinstalling a Transmission/Transaxle 23-6 • Lightly lubricate input shaft splines to ensure that there is no binding upon entering the clutch disc hub. Position all wires, hoses, and tubes out of the way and in their specified positions. Secure them temporarily if necessary.

23. Removing and Reinstalling a Transmission/Transaxle 23-6 • Following the specified procedure for the specific type of transmission/transaxle, reinstall the transmission/transaxle. Tighten all fasteners to the proper torque. If the vehicle is equipped with a cable- or linkage-style clutch release system, reinstall and adjust it for the proper free-play.

24. Removing and Reinstalling a Transmission/Transaxle 23-6 • If the vehicle is equipped with a hydraulic clutch, reinstall the slave cylinder and bleed and/or adjust if necessary.

25. Removing and Reinstalling a Transmission/Transaxle 23-6 • Refill the transmission/transaxle to the proper level with the specified fluid.

26. Removing and Reinstalling a Transmission/Transaxle 23-6 • Check that all electrical wires, connectors, linkages, and other removed components are properly installed and adjusted. Place exhaust hose(s) over the exhaust pipe(s) and set the parking brake.

27. Inspecting the Flywheel and Ring Gear 23-7 • Follow the specified procedure to remove the pressure plate and clutch disc. Remove the pressure plate bolts evenly, backing each bolt out one turn at a time to avoid warping the pressure plate. Have an assistant hold the pressure plate and clutch disc when they get close to becoming loose.

28. Inspecting the Flywheel and Ring Gear 23-7 • Clean up any debris using an approved method for disposing of hazardous dust. Use approved equipment and methods for the removal and disposal of clutch dust.

29. Inspecting the Flywheel and Ring Gear 23-7 • Inspect the flywheel for wear, hot spots, bluing, and cracks. Use of a straightedge can give a preliminary check for flatness.

30. Inspecting the Flywheel and Ring Gear 23-7 • Inspect the ring gear for wear, chipped teeth, and cracks. If teeth are worn in one area, it may also be necessary to replace the starter drive.

31. Inspecting the Flywheel and Ring Gear 23-7 • Check that the ring gear is secure on the flywheel.

32. Inspecting the Flywheel and Ring Gear 23-7 • Inspect the starter drive, as it may have been damaged from a faulty ring gear.

33. Measuring Flywheel Runout and Crankshaft End Play 23-8 • Following the specified procedure, measure flywheel runout. Mount the dial indicator base on the engine block and place the dial on the flywheel friction surface.

34. Measuring Flywheel Runout and Crankshaft End Play 23-8 • Rotate the crankshaft using a flywheel wrench or a socket and breaker bar. Find the high spot on the flywheel and zero the dial indicator. Continue rotating the crankshaft until the dial indicator reads the greatest amount of runout. Record your reading and compare with manufacturer specifications.

35. Measuring Flywheel Runout and Crankshaft End Play 23-8 • Following the specified procedure, measure crankshaft end play. Crankshaft end play should also be checked with a dial indicator to make sure it is not excessive; if it is, it should be addressed before replacing the clutch. Mount the dial indicator on the engine block surface and set the dial on the rear face of the crankshaft flange.

36. Measuring Flywheel Runout and Crankshaft End Play 23-8 • Carefully pry the crankshaft back and forth using a pry bar to pry on a bolt threaded into one of the crankshaft bolt holes. Record your reading and compare to manufacturer specifications.

37. Inspecting the Engine Block 23-9 • Mark the flywheel-to-crankshaft position. Remove the flywheel to access the rear of the engine. Inspect the engine block for obvious defects.

38. Inspecting the Engine Block 23-9 • Inspect the core plugs. Test their integrity by tapping on them lightly with a punch. Replace the core plugs if they are leaking or show signs of deterioration.

39. Inspecting the Engine Block 23-9 • Check the rear crankshaft oil seal for seepage, since this could leak onto the clutch assembly.

40. Inspecting the Engine Block 23-9 • Inspect the clutch (bell) housing for elongated holes or broken ears due to loose bolts. Inspect the transmission/transaxle case mating surfaces for flatness. Inspect the alignment dowels for proper fit, sizing, and wear. Check the engine block for stripped bolt holes that may have resulted from overtorquing.

41. Installing a Clutch Assembly 23-10 • Research the procedure. Inspect the pressure plate assembly for worn springs or diaphragm and also for irregularities associated with any kind of failure, including hot spots. Inspect the clutch disc for loose dampening springs or rubber blocks, and check the condition of the rivets.

42. Installing a Clutch Assembly 23-10 • Check the release (throw-out) bearing and linkage for damage or binding. Check the pilot bearing/ bushing for damage and its cavity. Determine any necessary action(s) for correcting failures, or replace any worn parts with new/ remanufactured components.

43. Installing a Clutch Assembly 23-10 • Following the specified procedure, install the pilot bushing/bearing, if removed. Lubricate it with the specified lubricant, if applicable.

44. Installing a Clutch Assembly 23-10 • Following the specified procedure, install the flywheel. Be sure to torque the flywheel bolts in the proper sequence.

45. Installing a Clutch Assembly 23-10 • Following the specified procedure, install the clutch disc and pressure plate. Use an appropriate clutch alignment tool to ensure proper positioning of the clutch disc.

46. Installing a Clutch Assembly 23-10 • Tighten the pressure plate bolts down evenly by tightening each bolt a turn or two, one at a time, until the pressure plate is evenly seated on the flywheel surface. Torque each pressure plate bolt according to the specified torque and sequence. Install the release (throw-out) bearing and linkage in the bell housing.