Clutch Inspection

INSPECTION

1. While observing clutch slave cylinder pushrod travel, have an assistant depress clutch pedal. Brake pedal should travel approximately 7.4 inches.
2. If slave cylinder pushrod moves .433 inch or more, hydraulic system is operating properly.
3. If slave cylinder pushrod did not move .433 inch, proceed as follows:
a. Check clutch master cylinder fluid level. The clutch slave cylinder must be installed during this operation. Refill as necessary.
b. If master cylinder requires fluid, check hydraulic system components for leakage. Remove rubber boots from cylinders and check for leakage past pistons. A slight wetting of piston and wall surfaces is acceptable.
c. If excessive leakage is indicated, entire hydraulic system must be replaced.

Fig. 2 Clutch Assembly:

Fig. 3 Aligning Clutch Disc & Pressure Plate:

REPLACEMENT

1. Disconnect battery ground cable.
2. Remove hush panel from driver's footwell, then disconnect clutch master cylinder pushrod from clutch pedal.
3. Remove transaxle as outlined under MANUAL TRANSAXLE procedure.
4. Mark position of pressure plate to flywheel to aid reassembly.
5. Gradually loosen pressure plate to flywheel attaching bolts until spring tension is relieved.
6. Support pressure plate and remove attaching bolts, pressure plate and driven disc, Fig. 2.
7. Clean pressure plate and flywheel mounting surfaces. Inspect bearing retainer outer surface of the transaxle.
8. Place pressure plate and driven disc in position and support with clutch alignment arbor tool No. J-29074, Fig. 3. The driven disc is installed with the damper springs offset toward the transaxle. Stamped letters found on the driven disc identify the ``Flywheel Side.''
9. Install and gradually torque the pressure plate to flywheel attaching bolts to 15 ft. lbs. Remove support tool.
10. Lubricate the clutch throwout fork where it contacts the release bearing and pack the release bearing inside diameter recess with suitable grease.
11. Install transaxle and hush panel, then connect battery ground cable.