Flywheel: Service and Repair

REMOVAL





1. Hold flywheel stationary with Special Tool (A) 09924-17810 and remove clutch cover bolts (1), clutch cover (2) and clutch disc.





2. Pull out input shaft bearing (3) by using Special Tool (B) 09917-58010 and wrench.

INSPECTION

Input Shaft Bearing
Check bearing for smooth rotation and replace it if abnormality is found.





Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Rivet head depth:
Standard: 1.6 mm (0.06 inch)
Service limit: 0.5 mm (0.02 inch)

Clutch Cover
1. Check diaphragm spring for abnormal wear or damage.
2. Inspect pressure plate for wear or heat spots.
3. If abnormality is found, replace it as assembly. Do not disassemble it into diaphragm and pressure plate.

Flywheel
Check surface contacting clutch disc for abnormal wear or heat spots. Replace or repair as required.

INSTALLATION

NOTE: Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.





1. Using Special Tool (A) 09924-17810, install flywheel (1) to crankshaft and tighten bolts (2) to (a) 78 Nm (56.5 ft. lbs.)





2. Using Special Tool (B) 09925-98210, install input shaft bearing to fly wheel.





3. Aligning clutch disc to flywheel center by using Special Tools (A) 09924-17810 and (C) 09923-36330, install clutch cover (3) and bolts. Then tighten bolts to (b) 23 Nm (17.0 ft. lbs.)

NOTE:
- While tightening clutch cover bolts, compress clutch disc with Special Tool (clutch center guide) by hand so that disc is centered.
- Tighten cover bolts little by little evenly in diagonal order.





4. Slightly apply grease "A" to input shaft, then join transmission transfer assembly with engine.

NOTE: Turn crankshaft with wrench from front while inserting transmission input shaft to clutch disc until splices mesh.