92Rocky-CL-Clutch-Part1
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DAIHATSU
Rocky
CLUTCH
CLUTCH RELEASE CL- CLUTCH PEDAL ADJUSTMENT CL- CLUTCH UNIT CL- TROUBLE SHOOTING CL
CLUTCH PEDAL CL-12
CLUTCH PEDAL & RELEASE
CABLE INSPECTION CL-15
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CLUTCH
CLUTCH
The clutch mechanism employs a dry, single-disc, diaphragm spring type. As for its operating method, it
adopts a cable method which features positive operation and excellent serviceability.
Pressure plate
Clutch release bearing hub
,Ciutch release lever yoke
Diaphragm spring
Clutch disc specifications
Clutch disc outer diameter
200 (7.87
Clutch disc inner diameter
140 (5.5
Flywheei side Thickness I -
3.5 (0,138
Pressure plate side
as (0138)
Lining surface area
160.14 (24.82)
Clutch cover specifications
Clutch cover outer diameter
mm (inch)
Diaphragm spring load as assembled
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CLUTCH
CLUTCH RELEASE
The clutch release lever yoke ls attached to the clutch release lever loy means of a bolt. Furthemore, an anti-vibration weight is provided at the outer lever section
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CLUTCH
CLUTCH PEDAL ADJUSTMENT
1. Check the clutch pedal for installation height.
Pedal installation height NOTE: ~ Ensure that the clutch pedal installation height is 5.8 mm (O.228 inch) higher than the brake pedal surface. Adjust the clutch pedal installation height, as required. Then, adjust the clutch pedal installation height to the following specification.
(Distance between pedal pact upper surfaces center and dash panel)
Clutch Pedal Installation Height:
221 im (8-700
NQTE: o The figure above indicates the dimension from the body metal section to the pedai. It is, therefore, necessary to roll up the carpet and floor mat prior to the measurement. Tightening Torque:
1.8 - 3.0 kg-m (13.0 - 21.7 ft-lb, 17.7 - 29.4 N-m)
2. Adjust the pedal installation height, as required.
(1) Slacken the lock nut. Turn the stopper bolt until the
installation height conforms to the specification. (2) Tighten the look nut. 3. Clutch pe-cial free travel
(1) Depress the clutch pedal gradually until you feel a resis
tance trcm the clutch. Measure the depressing distance up to this point. Specified Clutch Pedal Free Travel:
18 - 27 mm ((1709 - 1.063 inches)
If the free travel of the clutch pedal fails to conform to the
specification, adjust it to the specified value by changing the clip pos}tion of the ciutch cable.
Z
Body metai / gg
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CLUTCH
CLUTCH UNIT coMPoNENTs
- 15.9 - 21.6)
Clutch release lever yoke
Bush No. 1
Dust seal Release bearing hub clip on spring Bush No. 2 Clutch release bearing hub S/A Torsion spring Clutch cover assy Bolt Clutch disc assy Ilockplate , Bolt <6 plecies)
TROUBLE SHOOTING
Symptom
Possible causes
Remedies
Dragging clutch
Excessive free travel or clutch pedai travel improperly adjusted
Deformeci clutch disc
Clutch disc spline malfunctioning
Adjust free travel or clutch pedal travel.
Check clutch disc.
Check clutch disc.
Ciutch judder
Abnormal surface of clutch disc
Excessive runout of clutch disc
Unevenness of clutch cover diaphragm spring heights
Fauity clutch release bearing
Check clutch disc.
Check clutch disc runout.
Check clutch cover.
Check clutch release bearing,
O
Slipping clutch ,
Worn clutch disc
Excessively worn clutch pressure plate Faulty clutch cover diaphragm springs
Check clutch disc.
Check pressure plate. Check clutch cover.
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CLUTCH
REMOVAL
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 plate by means of a common tool of water
pump pliers. CAUTION: o Never reuse the removed lock washer.
4. Remove the bolt tightened tothe clutch release lever.
5. Remove the torsion spring from the release lever yoke,
using a standard screwdriver. NOTE: v Care must be exercised so that the torsion spring and standard screwdriver may not interfere with the release bearing hub clip when removing the torsion spring.
See page MT-Section.
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A
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CLUTCH
6. While pulling out the clutch release iever subassembly, / UWC
remove the torsion spring. / 7. Remove the clutch release Ieversubassembly, with the dust ///
seal attached, from the transmission case.
8. Removethe reiease 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 yoke from the release bearing
hub clip by turning the release lever yoke clockwise. CAUTION: ~ If the release bearing hub clip should be removed using a method other than the procedure above, it will cause the clip deformation.
10. Remove the tvvo bushes from the clutch housing.
/I W#
INSPECTION
1. Check the diaphragm spring for damage or wear.
af; aa
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CLUTCH
2. Check of clutch disc for vvear
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 (0.0118 inch)
3. Check of clutch disc for runout
Allowable Runout Limit
(Longitudinal Runout): 1.0 mm (0.0394 inch) (Lateral Runout): 0.7 mm ((10276 inch)
4. Check the following parts.
(1) Contact surface of release lever yoke with release bear
lng for wear (2) Release bearing hub clip for damage (3) lnner race of release bearing for Wear
5. Rotate the release bearing with your fingers. Ensure that the
release bearing rotates smoothly Without any binding. NOTE: ~ 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 Visuaily inspect whether the release bearing hub clip comes at the end sec-tion of the release lever yoke within the range indicated in the right figure.
Clutch disc
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CLUTCH
. Rotate the pilot bearing with your fingers. Prior to the instal- t
lation of the Clutch diso, ensure that the pilot bearing rotates /O O smoothly Without any binding. / /625 * As for the installation and removal ofthe pilot bearing, K LA JO
refer to the section.
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INSTALLATION KW/
o
1. Install the clutch disc. 0/-\uTloN; o Do not allow oil grease to get on the rubbing face. »
.1
2. Install the clutch cover, using the following SST. l g ssT: 09301-87601-ooo Qfage Tiqhtenino Torque: 1 FH Q
tightened evenly.
f
The right figure shows a typical example of tightening e
3. Check the oliapgragm spring fingers for unevenness .in _ height, using the following SST. 1')
Allowable Limit of Unevenness in Height:
0.8 mm (0.0315 inch) / SST: 09302-87702-ooo
4. If the inspection results reveal that the unevenness in height Kggx
' " A 'imit. correct the unevenness. usin
exceeds the allowable limit, correct the unevenness, using
the following SST.
SST: 0933300012-000
9 09333-00012-000
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CLUTCH
5.App|y Lithium base multi purpose grease to the entire
periphery ofthe inner surface of the bush.
6. Insert the bush into the transmission case.
Place the out-out section of the release lever yoke on the release bearing hub clip. Tum the release lever yoke oounterclockwise so as to set the clutch release bearing hub assembly, release bearing hub clip and release lever yoke. NOTE: v Prior to the setting, apply a suitable amount of Lithium base multi purpose grease (A section) to the clutch release bearing hub or to the sliding surface with the release lever yoke.
Apply molybdenum disuiphide lithium base grease to the surface of the front retainer bearing sliding section. CAUTION: Excessive application of grease may cause clutch slip
Page.
Attach the dust seal to the clutch release lever subassemb-
insert the clutch release lever subassembly into the trans- mission case.
Ali n the torsion spring with the stopper ofthe transmission S1 Cai, Aw
CL-10
fi
