Clutch Removal and Installation
Special Tools Required
Image Description/Tool Number
457221.png Bearing Driver Attachment, 37 x 40 mm 07746-0010200
310169.png Driver Handle, 15 x 135L 07749-0010000
609763.png Pressure Plate Compressor 07AAE-P8EA000
1149726.png 3.5 Engine Clutch Compressor Adapters 07AAE-P8EA220
609764.png Clutch Alignment Shaft 07AAF-P8EA000
609766.png Pressure Plate Compressor Adapter 07AAK-P8EA000
310223.png Ring Gear Holder 07LAB-PV00100

NOTE: You must use the pressure plate compressor, the 3.5 engine clutch compressor adapters, the clutch alignment shaft, and the pressure plate compressor adapter to remove and install the clutch pressure plate or you will damage it.

Engine Side

1. Transmission - Remove

Remove the transmission.

2. Height of Diaphragm Spring Finger - Check
Check the evenness of the height of the diaphragm spring fingers using the clutch alignment shaft, the pressure plate compressor adapter, and a feeler gauge (A). If the height difference is more than the standard, replace the pressure plate and the clutch disc as a set.

Standard (New):
0.6 mm (0.023 in) max.


3. Pressure Plate - Remove
1.
Install the clutch alignment shaft, the pressure plate compressor adapter, the pressure plate compressor, and the 3.5 engine clutch compressor adapters.
2.
Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.
3.
Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.
4.
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).
5.
Remove the pressure plate compressor, the pressure plate compressor adapter, and the 3.5 engine clutch compressor adapters, then remove the finger-tightened bolts and the pressure plate.

4. Pressure Plate - Inspect
1.
Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
2.
Inspect the pressure plate surface (A) for wear, cracks, and burning.

5. Clutch Disc - Remove
Remove the clutch disc (A), the clutch alignment shaft.


6. Clutch Disc - Inspect
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.
2.
Measure the clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc and the pressure plate as a set.
Standard (New):
8.68?9.53 mm (0.3417?0.3752 in)
Service Limit:
7.2 mm (0.283 in)
3.
Measure the depth of the rivet 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 the pressure plate as a set.
Standard (New):
1.0 mm (0.039 in) min.
Service Limit:
0.2 mm (0.008 in)

7. Flywheel - Inspect
1.
Inspect the ring gear teeth for wear and damage.
2.
Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
3.
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.
Standard (New):
0.05?0.45 mm (0.0020?0.0177 in)

8. Pilot Bearing - Check
Turn the inner race of the pilot bearing with your finger. The pilot bearing should turn smoothly and quietly. Check that the pilot bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the pilot bearing.


9. Flywheel - Remove
1.
Install the ring gear holder.
2.
Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder. Do not use impact tools to tighten the flywheel mounting bolts. Using impact tools may permanently damage the flywheel.

10. Pilot Bearing - Remove
Remove the pilot bearing (A).


Transmission Side

1. Transmission - Remove

Remove the transmission.

2. Release Bearing - Remove
1.
Remove the release fork boot (A).
2.
Remove the release fork (B) from the clutch housing (C) by squeezing the release fork set spring (D). Remove the release bearing (E).

3. Release Bearing - Check
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.



NOTE: The clutch disc and the pressure plate are a matched set and must be replaced together.

Engine Side

1. Pilot Bearing - Install
Install the pilot bearing (A) into the flywheel using the 15 x 135L driver handle and the 37 x 40 mm bearing driver attachment.


2. Flywheel - Install
1.
Install the flywheel (A) on the crankshaft, and install the mounting bolts finger-tight.
2.
Install the ring gear holder.
3.
Torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.
NOTE: Do not use impact tools to tighten the flywheel mounting bolts. Using impact tools may permanently damage the flywheel.
4.
Remove the ring gear holder.

3. Clutch Disc - Install
1.
Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B).
NOTE: Wipe off any excess grease.
2.
Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
3.
Install the clutch disc using the clutch alignment shaft.

4. Pressure Plate - Install
1.
Align the point marks (A) across the pressure plate (B) and the flywheel (C).
2.
Install the pressure plate and the mounting bolts (D) finger-tight.
3.
Install the pressure plate compressor adapter, the 3.5 engine clutch compressor adapters, and the pressure plate compressor.
4.
Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.
5.
Be careful not to damage the pressure plate (B). Tighten (180 degrees apart) the pressure plate mounting bolts (C) in the pattern as shown in several steps. Make sure that there is no clearance between the pressure plate and the flywheel.
Specified Torque:
 
26 N·m (2.7 kgf·m, 19 lbf·ft)
6.
Turn the center screw (A) on the pressure plate compressor counterclockwise by hand to release the pressure, then remove the pressure plate compressor, the pressure plate compressor adapter, the clutch alignment shaft, and the 3.5 engine clutch compressor adapters.
7.
Make sure the diaphragm spring fingers are all the same height.
8.
Do the release bearing inspection, and replace it if necessary.

5. Transmission - Install

Install the transmission.

Transmission Side

1. Release Bearing - Install
1.
Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.
NOTE:
Do not use silicone grease.
Replace the release fork bolt if necessary.
2.
Set the release fork set spring (E).
3.
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 in the clutch housing.
4.
Align the detent (C) of the release fork with the release fork bolt (D), then press the detent of the release fork over the release fork bolt squarely.
5.
Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.
6.
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.

2. Transmission - Install

Install the transmission.