F300-CL-Clutch-Part1
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DAIHATSU
CLUTCH
CLUTCH CL- 2 CLUTCH RELEASE CL- 3 CLUTCH PEDAL ADJUSTMENT CL- 4 CLUTCH UNIT CL- 5 COMPONENTS CL- 5 TROUBLE sHooTJNG cL- HEMOVAL cl.- :NsPEcT|oN |NsTAL1_AT|oN ca.- c|.uTcH PEDAL (L.H.D) cL-12 COMPONENTS CL-12 REMOVAL CL-13 INSPECTION (Clutch pedal & Release
cable) CL-15 FNSTALLATION CL--16 CLUTCH PEDAL (FI.H.D) CL-19 COMPONENTS CL-19 REMOVAL CL-20 INSPECTION CL-22 INSTALLATION (Clutch pedal & Fieiease
cable) CL-23
SERVICE SPECIFICATIONS CI.-26 TIGHT ENING TOROUE CL-26
WFEM-0.001
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CLUTCH
CLUTCH
The clutch mechanism employs a dry, single-disc, diaphragm spring type. As for its operating method, 'rt
adopts a cable method which features positive operation and excellent service-ability.
Fly wheel
Input shaft
i
Pressure plate
i , Clutch release lever yoke
Clutch release bearing hub
Diaphragm Spfing
Clutch disc specifications
Clutch disc outer diameter
200
I Clutch disc inner diameter
140
1 Thickness
3.5
I Pressure plate side
3.5
Lining surface area
160.14
Clutch cover specifications
"Crush cover uuier diameter
1 Diaphragm spring load as assembled
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CLUTCH
CLUTCH RELEASE
The clutch release lever yoke is anached to the clutch release iever by means of a bolt. Furthemore. an anti-vibration weight is provided at the outer Eever secti
Anti-vibration weight
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CLUTCH
CLUTCH PEDAL ADJUSTMENT
Check the clutch pedal for installation height Pedal installation height (Distance between pedal pad upper surfaces center and dash panel)
NOTE:
Ensure that the clutch pedal installaion height is 5.8 mm higher than me brake pedal surface. Adjust the clutch pedal installation height, as required. Then, adjust the clutch pedal installation heighho the following specitica- tion. The ligure above is ihe dimension form the body metal section to the pedal. It is, Iherefore, necessary 10 roll up the carpet and floor mat prior tothe measurement. 'Fghtening Torque: 17.7 - 29.4 N-m (1.8 - 3.0 kgf-m)
Adjust the pedal installation height, as required. (1) Slacken the lock nut Tum the stopper bolt until the
installation height conforms to the specification.
(2) 'lighten the Jock nut. Clutch pedal free travet (1) Depress the clutch pedal gradually until you feel a resis
pedal gracuauy unm you tee: a resrs- tance from the clutch. Measure the depressing distance up to this point. Specilied Clutch Pedal Free Travel: 18 - 27 mm
lf the free travel of the clutch pedal fails to confon'n to the specification, aciiust it to the specified value by changing the clip position of The clutch cable.
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CLUTCH UNIT comPoNEN1's
Clutch release fork lever SJ!
Remedies
Dragging clutch
0 Symptom
V
1 o Excessive iree travel or clutch pedal 'K
travel improperly adjusted
I Deformed clutch disc
v Clutch disc spline malfunctioning
Adjust hee travet or clutch pecial travel.
Check clutch ciisc.
Check clutch disc.
- Abnormaf surface of ciutch disc
Excessive runout of clutch disc
v Unevenness of clutch cover diaphragm
spring heights
- Faurty clutch release bearing
ChBCk clutch disc.
Check clutch disc runout.
Check clutch cover.
Check ciutch release bearing.
snpping clutch 1 .
Excessively wom clutch pressure piate
v Faulty clutch cover diaphragm springs
Check clutch disc.
Check pressure plate.
Check clmch cover.
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CLUTCH
1. Remove the transmission from the vehicle.
2. Remove the clutch disc by removing the clutch cover with
the six bolts.
3. Raise the lock piate by means of a common tool of water
pump pliers. CAUTION: 0 Never reuse the lock washer.
4. Remove the bolt tightened to the clutch release lever.
5. Remove the torsion spring from the release lever yoke,
using a standard screwdriver. NOTE: 0 Care must be exercised so that the torsion spring and standard screwdriver may not interfere with the reiease bearing hub clip when removing the torsion spring.
See page MT-Section.
If
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CLUTCH
6. While pulling out the clutch release lever subassembiy, 1
remove the torsion spring. l 7. Remove the clutch release lever subassembiy, with the dust 1 `
seal attached, from the transmission case.
__
_ -- Torsion J
><spring
8. Remove the release lever yoke, release bearing hub clip and clutch release bearing hub assembly as a set from the
front bearing retainer.
9. Remove the release lever y
hub clip by turning the release lever yoke clockwise.
U
CAUTION: _ . If the release bearing hub clip should be removed using N/
a method other than the procedure above, it wiil cause .
I 1 i
the clutch housing
10. Remove the two bushes from the clutch housinu.
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INSPECTION
1. Check the diaphragm spring for damage or wear.
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2. Check of clutch disc lor wear
Measure the height of the clutch disc from each rivet. Com- pare the lowest height against the the allowable use limit below.
Allowable Use Limit 0.3 mm
3. Check of clutch disc for runom
Allowable Runout Limit
(Longitudinal Runout): 1.0 mm (Lateral Flunout): 0.7 mm
4. Check the following parts.
(1) Contact surface of release lever yoke with release bear
ing for wear (2) Release bearing hub clip for damage
5. Rotate the reiease bearing with your fingers. Ensure that the
release bearing rotates smoothly without any binding. NOTE: v Since the release bearing is packed with grease, never
clean it, using oil.
6. Assemble the release lever yoke, release bearing hub clip and clutch release bearing hub assembly as a set. (See page CL-10.) o Visually inspect whether the release bearing hub clip comes at the end section of the release lever yoke within the range indicated in the right Hgure.
(1)
(3) ing for wear == (2) (2) Release bearing hub clip for damage (3) Inner race of reiease bearing for wear V - F
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. T. Rotate the pilot bearing with your fingers. Prior to the instal
lation of the clutch disc, ensure that the piiot bearing rotates smoothly without any binding.
* As for the installation and removal of the pilot bearing,
refer to the EM section.
INSTALLATION
1. Install the cluich disc.
CAUTION: o Do not aliow oil grease to get on the rubbing face.
2. Install the clutch cover. using the foilowing SST.
SST: 09301-87601-000 1`|ghtening Torque: 14.7 - 21.6 N-m (1.5 - 2.2 kgf-rn)
CAUTION: o Be sure to tighten the bolts diagonally wiihin the tighten
ing torque range above so that the clutch cover may be lightened evenly.
(The right Ggure shows a typical example of tightening sequeme.)
3. Check the diapgragm spring fingers for unevenness in
height, using the following SST. . Albowabie Limit of Unevenness in Height 0.8 mm
SST: 09302-87702-O00
4. If the inspection results reveal that the unevenness in height exceeds the allowable limit, correct the unevenness, using the following SST.
SST: 09333-00012-000
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5. Apply Lithium base multi purpose grease to the entire
periphery of the inner surface of the bush. 6. Insert the bush into the transmission case.
7. Place the cut-out section of the release lever yoke on the release bearing hub clip. Turn the release lever yoke counterclockwise so as to sei the clutch release bearing hub assembly. release bearing hub clip and release lever yoke. NOTE: . Prior to the setting, appty a suitable amount of Lithium base multi purpose grease (A section) to the ciutch release bearing hub or to the sliding surface with the release lever yoke.
8. Apply molybdenum disulphide lithium base grease to the
surface of the front retainer bearing sliding section. CAUTION: - Excessive application of grease may cause clutch slip
Page.
9. Attach the dust seal to the clutch release lever subassemb
ly. 10. Insert the clutch release lever subassembly into the trans
mission case.
11. Align the torsion spring with the stopper of the transmission
case.
