Hydraulic clutch control consists of hydraulic master cylinder, slave cylinder, reservoir, and connecting tubing. Clutch disc and pressure plate are single disc type. Clutch release bearing or bearing arm is activated by hydraulic pressure. Pilot bearing is mounted in flywheel and requires no lubrication unless clutch assembly is serviced. No adjustment of clutch linkage or pedal position is required.
PRESSURE PLATE & CLUTCH DISC
Remove transmission. Mark pressure plate and flywheel for reassembly reference. Loosen bolts holding pressure plate to flywheel evenly until springs are expanded. Remove pressure plate and clutch disc from flywheel.
Clean pressure plate and flywheel surface with commercial alcohol base solvent. Place clutch disc on flywheel. Align disc center with pilot bearing using old input shaft or clutch pilot shaft. Place pressure plate on flywheel and align marks made during disassembly.
Tighten bolts evenly in clockwise rotation. Tighten every other bolt for first 3 bolts, then skip to fourth bolt, then every other bolt until all 6 bolts are tightened. Remove clutch pilot shaft. Reverse removal procedure to complete installation.
CLUTCH RELEASE BEARING
Remove transmission. Remove clutch release lever from stud in bellhousing. Remove release bearing and hub from lever. Check bearing for any roughness and replace if necessary. Check bore of bearing hub for burrs or scoring that could bind on input shaft retainer.
Before installing bearing, fill annular groove with lithium base grease. Lightly coat inside diameter of release bearing. Lightly lubricate fingers and fulcrum point of release lever. Position release lever on pivot stud in bellhousing.
CLUTCH PILOT BEARING
Remove transmission, pressure plate, and clutch disc. Use Slide Hammer (T59L-100-B) and Puller (T58L-101-A) to remove pilot bearing.
Lightly coat crankshaft bore with lithium base grease. Using Clutch Aligner (T71P-7137-H) and Bearing Driver (T74P-7137-A), install pilot bearing with seal toward transmission. Install clutch disc, pressure plate, and transmission. Use care when installing transmission so that input shaft does not damage pilot bearing.
NOTE:Use Bearing Driver (T74P-7137-C) on 2.3L engine.
CLUTCH HYDRAULIC SYSTEM
NOTE:On all models, disconnect master cylinder push rod if slave cylinder is to be disconnected from release lever or bearing. Permanent damage to slave cylinder will occur if master cylinder is activated with slave cylinder disconnected.
Disconnect pedal return spring from pedal and bracket. Unhook barbed end of clutch/starter interlock switch from pedal. Remove clutch pedal after removing retaining nut on end of shaft. Remove bushing from pedal shaft.
Install bushing on shaft. Place pedal on shaft and tighten nut. Install return spring. Make sure spring is hooked to pedal and bracket securely. Insert barbed end of interlock switch rod into bracket. Check and adjust interlock switch if necessary.
Thursday, January 22nd, 2009 AT 7:27 AM