CLUTCH UNIT REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (4WD)

  3. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY (4WD)

  4. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (4WD)

  5. REMOVE REAR PROPELLER SHAFT ASSEMBLY

  6. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

  7. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

  8. REMOVE CLUTCH RELEASE FORK BOOT

  9. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

  10. REMOVE RELEASE BEARING HUB CLIP

  11. REMOVE RELEASE FORK SUPPORT


    1. Remove the release fork support from the manual transmission unit.

  12. REMOVE CLUTCH COVER ASSEMBLY


    1. A01DVT8E01

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  13. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  14. INSPECT INPUT SHAFT FRONT BEARING


    1. A01DYKTE01

      Turn the bearing by hand by applying rotational force.

      If the bearing sticks or has much resistance, replace the input shaft bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.

  15. REMOVE INPUT SHAFT FRONT BEARING


    1. A01DXTUE01

      Remove any 2 diametrically opposite bolts.

    2. Using SST, remove the input shaft bearing.

      SST
      09303-35011

  16. INSPECT CLUTCH DISC ASSEMBLY

    Note

    When replacing the clutch disc assembly, make sure to perform an inspection of the flywheel subassembly and clutch cover assembly.


    1. A01DYG9E01

      Using a vernier caliper, measure the rivet head depth.

      Minimum rivet depth
      0.3 mm (0.012 in)

      If the depth is less than the minimum, replace the clutch disc assembly.

    2. A01DXLJE01

      Install the clutch disc to the transmission unit.

      Note

      Be careful not to insert the clutch disc facing the wrong direction.

    3. Using a dial indicator, check the disc runout.

      Maximum runout
      0.8 mm (0.031 in.)

      If the runout is greater than the maximum, replace the clutch disc assembly.

  17. INSPECT CLUTCH COVER ASSEMBLY


    1. A01E0IUE01

      Using a vernier caliper, measure the depth and width of the worn areas of the diaphragm spring.

      Maximum
      Measurement Maximum
      A (Depth) 0.5 mm (0.020 in.)
      B (Width) 6.0 mm (0.236 in.)

      If the depth or width is greater than the maximum, replace the clutch cover assembly.

      Note

      When replacing the clutch disc assembly, make sure to perform an inspection of the flywheel subassembly and clutch cover assembly.

  18. INSPECT FLYWHEEL SUB-ASSEMBLY


    1. A01DYQIE01

      Using a dial indicator, measure the flywheel runout.

      Maximum runout
      0.1 mm (0.004 in.)

      If the runout is greater than the maximum, replace the flywheel sub-assembly.

      Note

      When replacing the clutch disc assembly, make sure to perform an inspection of the flywheel subassembly and clutch cover assembly.

  19. INSPECT CLUTCH RELEASE BEARING ASSEMBLY


    1. A01DVA6E01

      Turn the bearing by hand while applying force in the axial direction.

      If the bearing sticks or has much resistance, replace the release bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.