Symptom Suspect Area See page 5. Engine mounting (Loosen) 6. Clutch disc assy (Runout is excessive) 7. Clutch disc assy (Oily)
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1 CLUTCH CLUTCH SYSTEM (MTM) PROBLEM SYMPTOMS TABLE HINT: CLUTCH SYSTEM (MTM) Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 5. Engine mounting (Loosen) 6. Clutch disc assy (Runout is excessive) 7. Clutch disc assy (Oily) Clutch grabs/chatters 8. Clutch disc assy (Worn out) 9. Clutch disc torsion rubber (Damaged) 10.Clutch disc assy (Glazed) 11.Diaphragm spring (Out of tip alignment) Clutch pedal spongy 1. Clutch Line (Air in line) 2. Master cylinder cup (Damaged) 3. Release cylinder rubber (Damaged) Clutch noisy 1. Clutch release bearing assy (Worn, dirty, or damaged) Clutch disc torsion rubber (Damaged) Clutch pedal (Free play out of adjustment) 2. Clutch disc assy (Oily) Clutch slips 3. Clutch disc assy (Worn out) Diaphragm spring (Damaged) Pressure plate (Distortion) 6. Flywheel subassy (Distortion) Clutch pedal (Free play out of adjustment) 2. Clutch line (Air in line) 3. Master cylinder cup (Damaged) 4. Release cylinder cup (Damaged) Clutch does not disengage 5. Clutch disc assy (Out of true) Clutch disc assy (Runout of excessive) Clutch disc assy (Lining broken) 8. Clutch disc assy (Dirty or burned) 9. Clutch disc assy (Oily) 10.Clutch disc assy (Lack of spline grease) K
2 422 CLUTCH CLUTCH PEDAL SUBASSY (MTM) ADJUSTMENT CLUTCH PEDAL SUBASSY (MTM) 4203L01 1. INSPECT AND ADJUST CLUTCH PEDAL SUBASSY (a) Turn over the floor carpet. Push Rod Play and Free Play Adjust Point Pedal Height Adjust Point Push Rod Play (b) (c) (d) Check that the pedal height is correct. Pedal height from asphalt sheet: mm ( in.) Adjust the pedal height. (1) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. Torque: 24.5 N m (245 kgf cm, 18 ft lbf) Check that the pedal free play and push rod play are correct. (1) Depress the pedal until the clutch resistance begin to be felt. Pedal free play: mm ( in.) (2) Gently depress the pedal until the resistance begins to increase a little. Push rod play at pedal top: mm ( in.) Pedal Height D26341 Pedal Free Play CL0102 (e) Adjust the pedal free play and push rod play. (1) Loosen the lock nut and turn the push rod until the free play and push rod play are correct. (2) Tighten the lock nut. (3) After adjusting the pedal free play, check the pedal height. (4) Connect the air duct and install the lower finish panel. 1499
3 CLUTCH CLUTCH PEDAL SUBASSY (MTM) 423 Full Stroke End Position 25 mm (0.98 in.) or more Release Point CL0512 (f) Check the clutch release point. (1) Pull the parking brake lever and install wheel stopper. (2) Start the engine and idle the engine. (3) Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. (4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operations. Check pedal height. Check push rod play and pedal free play. Bleed the clutch line. Check the clutch cover assy and disc assy. 1500
4 424 CLUTCH CLUTCH PEDAL SUBASSY (MTM) COMPONENTS 4203M01 Clutch Master Cylinder Push Rod Clevis w/ Hole Pin 19.1 (195, 14) Clip 36.8 (375, 27) Clutch Pedal Support Subassy Clutch Pedal Spring Clutch Pedal Bush 11.8 (120, 9) Clutch Start Switch Assy Connector Clutch Pedal Bush Clutch Pedal No.1 Cushion Clutch Master Cylinder Push Rod Clevis Bush N m (kgf cm, ft lbf) : Specified torque Nonreusable part MP Grease Clutch Pedal Subassy Clutch Pedal Subassy Clutch Pedal Pad D
5 CLUTCH CLUTCH PEDAL SUBASSY (MTM) REPLACEMENT 1. REMOVE INSTRUMENT PANEL SUBASSY LOWER (See page 7110) 2. REMOVE CLUTCH PEDAL SPRING N02 3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Remove the clip and hole pin. D REMOVE CLUTCH PEDAL SUPPORT SUBASSY (a) w/ Cruise control: Disconnect the clutch switch assy connector. (b) Disconnect the clutch start switch assy connector. (c) Remove the 2 nuts, bolt and clutch pedal support assy. D REMOVE CLUTCH PEDAL SUBASSY (a) Remove the bolt and nut. (b) Remove the clutch pedal subassy from the clutch pedal support. D REMOVE CLUTCH PEDAL PAD 1502
6 426 CLUTCH CLUTCH PEDAL SUBASSY (MTM) 7. REMOVE CLUTCH PEDAL BUSH (a) Remove the 2 bushes from the clutch pedal. D REMOVE CLUTCH PEDAL NO.1 CUSHION (a) Using needlenose pliers, remove the No.1 cushion from the clutch pedal. D REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH (a) Using a 8 mm hexagon wrench and a hammer, remove the clevis bush from the clutch pedal subassy. D INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH (a) Apply MP grease to inside of a new clevis bush. (b) Install the clevis bush to the clutch pedal. HINT: Install the clevis bush from the right side of the vehicle. MP Grease D INSTALL CLUTCH PEDAL NO.1 CUSHION (a) Using needlenose pliers, install the No.1 cushion to the clutch pedal. D
7 CLUTCH CLUTCH PEDAL SUBASSY (MTM) INSTALL CLUTCH PEDAL BUSH (a) Apply MP grease to both side of 2 new bushes. (b) Install the 2 bushes to the clutch pedal. MP Grease D INSTALL CLUTCH PEDAL PAD 14. INSTALL CLUTCH PEDAL SUBASSY (a) Install the clutch pedal subassy to the clutch pedal support with the bolt and nut. Torque: 36.8 N m (375 kgf cm, 27 ft lbf) HINT: Install the bolt from the right side of the vehicle. D INSTALL CLUTCH PEDAL SUPPORT SUBASSY (a) Install the clutch pedal support to the vehicle with the 2 nuts and bolt. Torque: Bolt: 19.1 N m (195 kgf cm, 14 ft lbf) Nut: 11.8 N m (120 kgf cm, 9 ft lbf) (b) Connect the clutch start switch assy connector. (c) w/ Cruise control: Connect the clutch switch assy connector. D26343 MP Grease D INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Apply MP grease to the contact surface of the hole pin and clevis bush. (b) Connect the clevis to the clutch pedal subassy with the hole pin. HINT: Install the hole pin from the right side of the vehicle. (c) Install the clip to the hole pin. 1504
8 428 CLUTCH CLUTCH PEDAL SUBASSY (MTM) 17. INSTALL CLUTCH PEDAL SPRING 18. INSTALL INSTRUMENT PANEL SUBASSY LOWER 19. INSPECT SRS WARNING LIGHT (See page 05424) 20. INSPECT AND ADJUST CLUTCH PEDAL SUBASSY (See page 422) 1505
9 CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM) CLUTCH MASTER CYLINDER ASSY (MTM) COMPONENTS O01 Clutch Master Cylinder Push Rod Clevis w/ Hole Pin Clutch Reservoir Tube Clip Inlet Union Grommet Slotted Spring Pin Stop Plate Boot Clevis Clip 15.2 (155, 11) Push Rod Lock Nut 24.5 (245, 18) Spring Piston Snap Ring Master Cylinder Body 11.8 (120, 9) Clutch Pedal Spring N m (kgf cm, ft lbf) : Specified torque Nonreusable part Lithium soap base glycol grease MP grease D
10 4210 CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM) OVERHAUL 1. DRAIN CLUTCH FLUID 2. REMOVE BRAKE MASTER CYLINDER SUBASSY (See page 3213) 3. REMOVE BRAKE BOOSTER ASSY (See page 3220) 4203P02 4. DISCONNECT CLUTCH RESERVOIR TUBE (a) Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder assy. HINT: Use a container to catch the fluid. D07708 SST 5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, disconnect the flexible hose tube. SST HINT: Use a container to catch the fluid. D REMOVE CLUTCH PEDAL SPRING 7. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Remove the clip and hole pin. D REMOVE CLUTCH MASTER CYLINDER ASSY (a) Remove the 2 nuts and clutch master cylinder assy. 1507
11 CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM) REMOVE CLUTCH MASTER CYLINDER KIT (a) Using a pin punch and a hammer, drive out the slotted spring pin. (b) Remove the inlet union and grommet. (c) Loosen the lock nut, and remove the clevis. (d) Remove the lock nut from the push rod. (e) Remove the boot from the cylinder body. D07728 CL0533 (f) While pushing the push rod, using snap ring pliers, remove the snap ring. (g) Remove the push rod from the cylinder body. NOTICE: The piston may pop up out of the cylinder body. Therefore, slowly remove the push rod from the cylinder body. (h) Remove the stop plate from the push rod. (i) Remove the piston with spring from the cylinder. NOTICE: Be careful not to damage the inside of the cylinder body. 10. INSTALL CLUTCH MASTER CYLINDER KIT (a) Coat parts with lithium soap base glycol grease, as shown in the illustration. (b) Install the piston with spring into the cylinder. NOTICE: Be careful not to damage the inside of the cylinder body. (c) Install the stop plate to the push rod. (d) Install the push rod to the cylinder body. CL0528 (e) (f) (g) (h) (i) While pushing the push rod, using snap ring pliers, install the snap ring. Install the boot to the cylinder body. Install the lock nut to the push rod. Temporarily install the clevis with the lock nut to the push rod. Install the inlet union and a new grommet. CL
12 4212 CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM) Protrusion mm ( in.) (j) Using a pin punch and a hammer, drive in the slotted spring pin. D INSTALL CLUTCH MASTER CYLINDER ASSY (a) Install the clutch master cylinder assy with the 2 nuts. Torque: 11.8 N m (120 kgf cm, 9 ft lbf) MP Grease D INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN (a) Apply MP grease to the contact surface of the hole pin and clevis bush. (b) Connect the clevis to the clutch pedal subassy with the hole pin. HINT: Install the hole pin from the right side of the vehicle. (c) Install the clip to the hole pin. 13. INSTALL CLUTCH PEDAL SPRING SST 14. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, connect the flexible hose tube. SST Torque: 15.2 N m (155 kgf cm, 11 ft lbf) D CONNECT CLUTCH RESERVOIR TUBE (a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assy. NOTICE: Facing the white mark upward. White Mark D
13 CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM) INSTALL BRAKE BOOSTER ASSY (See page 3220) 17. INSTALL BRAKE MASTER CYLINDER SUBASSY (See page 3213) 18. BLEED BRAKE LINE (See page 324) 19. BLEED CLUTCH PIPE LINE (a) Fill the brake reservoir tank with clutch fluid and bleed clutch system. Torque: 8.4 N m (85 kgf cm, 73 in. lbf) 20. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 326) 21. INSPECT AND ADJUST CLUTCH PEDAL SUBASSY (See page 422) 22. CHECK BRAKE FLUID LEAKAGE 23. CHECK CLUTCH FLUID LEAKAGE 24. CHECK FLUID LEVEL IN RESERVOIR 1510
14 4214 CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM) CLUTCH RELEASE CYLINDER ASSY (MTM) COMPONENTS 4203Q (51, 44 in. lbf) 15.2 (155, 11) Flexible Hose Tube 11.8 (120, 9) Flexible Hose Tube Bracket Bleeder Plug 8.4 (85, 74 in. lbf) Release Cylinder Bleeder Plug Cap Release Cylinder Body Piston Push Rod Spring Boot N m (kgf cm, ft lbf) : Specified torque Nonreusable part Lithium soap base glycol grease D
15 CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM) 4215 OVERHAUL 1. DRAIN CLUTCH FLUID 4203R01 2. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, disconnect the flexible hose tube. SST HINT: Use a container to catch the fluid. SST D REMOVE CLUTCH RELEASE CYLINDER ASSY (a) Remove the 3 bolts, clutch release cylinder assy and clutch line bracket. D REMOVE CLUTCH RELEASE CYLINDER KIT (a) Remove the boot from the cylinder body. (b) Remove the push rod from the cylinder body. (c) Remove the piston from the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (d) Remove the spring from the cylinder body. (e) Remove the bleeder plug cap from the bleeder plug. 5. REMOVE RELEASE CYLINDER BLEEDER PLUG 6. INSTALL RELEASE CYLINDER BLEEDER PLUG Torque: 8.4 N m (85 kgf cm, 74 in. lbf) 1512
16 4216 CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM) 7. INSTALL CLUTCH RELEASE CYLINDER KIT (a) Install the bleeder plug cap to the bleeder plug. (b) Install a new spring to the cylinder body. (c) Coat parts with lithium soap base glycol grease, as shown in the illustration. (d) Install the piston to the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. (e) Install the push rod to the cylinder body. (f) Install the boot to the cylinder body. CL INSTALL CLUTCH RELEASE CYLINDER ASSY (a) Install the clutch release cylinder and clutch line bracket with the 2 bolts. Torque: 11.8 N m (120 kgf cm, 9 ft lbf) (b) Install the flexible hose tube with the bolt. Torque: 5.0 N m (51 kgf cm, 44 in. lbf) D CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, connect the flexible hose tube. SST Torque: 15.2 N m (155 kgf cm, 11 ft lbf) SST D BLEED CLUTCH PIPE LINE (a) Fill the brake reservoir tank with brake fluid and bleed clutch system. Torque: 8.4 N m (85 kgf cm, 74 in. lbf) 11. CHECK CLUTCH FLUID LEAKAGE 1513
17 CLUTCH CLUTCH UNIT (MTM) 4217 CLUTCH UNIT (MTM) COMPONENTS 4203S01 Clutch Disc Assy 19.1 (195, 14) Clutch Release x6 Fork Subassy Clutch Release Bearing Assy Release Bearing Hub Clip Flywheel Subassy Clutch Cover Assy Release Fork Support 36.8 (375, 27) Clutch Release Fork Boot N m (kgf cm, ft lbf) : Specified torque Clutch spline grease Release hub grease D
18 4218 CLUTCH CLUTCH UNIT (MTM) OVERHAUL 1. REMOVE MANUAL TRANSAXLE ASSY (See page 4117) 4203T01 2. REMOVE CLUTCH RELEASE FORK SUBASSY (a) Remove the clutch release fork with clutch release bearing from the transaxle assy. Q REMOVE CLUTCH RELEASE BEARING ASSY (a) Remove the clutch release bearing assy from the clutch release fork. 4. REMOVE RELEASE FORK SUPPORT (a) Remove the release fork support from the transaxle assy. 5. REMOVE RELEASE BEARING HUB CLIP 6. REMOVE CLUTCH RELEASE FORK BOOT C62955 Matchmarks D REMOVE CLUTCH COVER ASSY (a) Align the matchmarks on the clutch cover assy with the one on the flywheel subassy. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the 6 bolts, and pull off the clutch cover assy. NOTICE: Do not drop the clutch disc assy. 8. REMOVE CLUTCH DISC ASSY NOTICE: Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel subassy away from oil and foreign attachment. C INSPECT CLUTCH DISC ASSY (a) Using vernier calipers, measure the rivet head depth. Maximum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc assy. (b) Install the clutch disc assy to the transaxle assy. NOTICE: Take care not to insert the clutch disc assy in the wrong direction. 1515
19 CLUTCH CLUTCH UNIT (MTM) 4219 Transaxle Side (c) Using a dial indicator, check the clutch disc assy runout. Minimum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc assy. D26338 A B 10. INSPECT CLUTCH COVER ASSY (a) Using vernier calipers, inspect the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) If necessary, replace clutch cover assy. C57466 D INSPECT FLYWHEEL SUBASSY (a) Using a dial indicator, inspect the flywheel subassy runout. Maximum runout: 0.1 mm (0.004 in.) If necessary, replace the flywheel subassy. C INSPECT CLUTCH RELEASE BEARING ASSY (a) Turn the release bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing assy. Q01060 Flywheel Side 13. INSTALL CLUTCH DISC ASSY (a) Insert SST in the clutch disc assy, then insert them in the flywheel subassy. SST NOTICE: Take care not to insert clutch disc assy in the wrong direction. SST D
20 4220 CLUTCH CLUTCH UNIT (MTM) SST (Temporally), 4 5 Matchmarks D INSTALL CLUTCH COVER ASSY (a) Align the matchmarks on the clutch cover assy and flywheel subassy. (b) Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top. Torque: 19.1 N m (195 kgf cm, 14 ft lbf) HINT: Following the order in the illustration, tighten the bolts at a time evenly. Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts. SST 15. INSPECT AND ADJUST CLUTCH COVER ASSY (a) Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum nonalignment: 0.5 mm (0.020 in.) If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment. SST D INSTALL RELEASE FORK SUPPORT (a) Install the release fork support to the transaxle assy. Torque: 36.8 N m (375 kgf cm, 27 ft lbf) 17. INSTALL RELEASE BEARING HUB CLIP Release hub grease D INSTALL CLUTCH RELEASE FORK SUBASSY (a) Apply release hub grease to the release fork and release bearing assy contact, release fork and push rod contact and release fork pivot points. Sealant: Part No , RELEASE HUB GREASE or equivalent (b) Install the release fork to the release bearing assy. 19. INSTALL CLUTCH RELEASE BEARING ASSY (a) Apply the clutch spline grease to the input shaft spline. Sealant: Part No , CLUTCH SPLINE GREASE or equivalent (b) Install the bearing to the release fork, and then install them to the transaxle assy. NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly. 1517
21 CLUTCH CLUTCH UNIT (MTM) INSTALL CLUTCH RELEASE FORK BOOT 21. INSTALL MANUAL TRANSAXLE ASSY (See page 4117) 1518
22 4222 CLUTCH CLUTCH START SWITCH ASSY (MTM) ONVEHICLE INSPECTION CLUTCH START SWITCH ASSY (MTM) CHECK CLUTCH START SYSTEM (a) Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch assy. Clutch Start Switch Assy D
23 CLUTCH CLUTCH START SWITCH ASSY (MTM) 4223 INSPECTION INSPECT CLUTCH START SWITCH ASSY (a) Check the continuity between the terminals when the switch is ON and OFF. Switch position ON (pushed) OFF (free) Condition Continuity No continuity mm ( in.) D
24 4224 CLUTCH CLUTCH START SWITCH ASSY (MTM) REPLACEMENT 1. REMOVE CLUTCH START SWITCH ASSY (a) Disconnect the clutch start switch assy connector. (b) Remove the nut and clutch start switch assy from the clutch pedal support. 2. INSTALL CLUTCH START SWITCH ASSY (a) Install the clutch start switch assy with the nut. Torque: N m (160 kgf cm, 12 ft lbf) (b) Connect the clutch start switch assy connector. 3. INSPECT CLUTCH START SWITCH ASSY (See page 4222) 4203U
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If it exceeds the maximum specification, replace the propeller shaft.
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