Clutch Replacement

Special Tools Required Pressure plate compressor 070AF-RBDA100 Clutch alignment shaft 070AF-RAWA140
Pressure plate compressor adapter
07AAK-P8EA000
Attachment, 37 x 40 mm
07746-0010200
Driver
07749-0010000
You must use the special tools required to remove and install the clutch pressure plate or you will irreversibly damage it.
Pressure Plate and Clutch Disc Removal

1. Check the height of the diaphragm spring fingers using the special tools and a feeler gauge. If the height is more than the service limit, replace the pressure plate and clutch disc as a set.

   Standard (New): | 0.6 mm (0.02 in.) max.
   Service Limit: | 0.8 mm (0.03 in.)

1. Install the special tools.

1. Turn the center screw (A) 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 on the pressure plate compressor counterclockwise by hand to release the pressure, then install two pressure plate mounting bolts, hand-tight, to hold the pressure plate (B). Remove the special tools and the pressure plate.

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

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

1. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage 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.)

1. Remove the clutch disc and special tools.

1. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is soaked with oil, replace it. Find the source of the oil leak if the clutch disc is soaked.

1. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc and pressure plate as a set.

   Standard (New): | 8.68−9.53 mm (0.342−0.375 in.)
   Service Limit: | 7.2 mm (0.283 in.)

1. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth 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.)
   Service Limit: | 0.2 mm (0.008 in.)

Flywheel and Pilot Bearing Inspection

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 the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is not within the standard, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended.

   Standard (New): | 0.05−0.45 mm (0.002−0.018 in.)

1. 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 fits tightly in the flywheel, replace the pilot bearing.

Flywheel and Pilot Bearing Replacement You must not use the impact wrench required to install and remove the flywheel mounting bolts or you will irreversibly damage the flywheel.

1. Install the special tool.

1. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.

1. Remove the pilot bearing (A) from the flywheel (B).

1. Install the new pilot bearing (A) into the flywheel using the special tools. Apply a light coat of oil to the bearing outer surface.

1. Install the flywheel and mounting bolts, finger-tight.

1. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.
   NOTE: When installing the flywheel mounting bolts, apply engine oil to the seat surface of the flywheel mounting bolts.

Clutch Disc and Pressure Plate Installation

1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.

1. Install the ring gear holder.

1. Apply urea grease UM264 (P/N 41211-PY5-305) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools.

1. Align a point mark (A) across the pressure plate (B) and flywheel (C).

1. Install the pressure plate (B) and the mounting bolts (D), finger-tight.

1. Install the special tools.

1. Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring.Continue turning the center screw unit it stops.

1. Be careful not to damage the pressure plate (A). Tighten (180 degrees apart) the pressure plate mounting bolts (B) in a star pattern in several steps.

   Pressure Plate Mounting Bolt 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, then remove the special tools.

1. Make sure the diaphragm spring fingers are all the same height.

Release Bearing Replacement

1. Remove the release fork boot (A) from the clutch housing (B).

1. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D). Remove the release bearing (E).

1. Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one.
   NOTE: The release bearing is packed with grease. Do not wash it in solvent.

1. Apply urea grease UM264 (P/N 41211-PY5-305) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release fork set spring (D), in the shaded areas.

1. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.

1. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely.

1. Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.

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