CLUTCH DISC AND CLUTCH COVER

< UNIT REMOVAL AND INSTALLATION >

R9M : Exploded View INFOID:0000000010288579

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1. Manual Transmission 2. Concentric slave cylinder (CSC) 3. Bolt

4. Clutch assembly bolt 5. Spacer 6. Clutch cover
7. Clutch disc 8. Flywheel
Refer to GI-4, "Components" for symbols not described on the above.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

R9M : Removal and Installation INFOID:0000000010288580

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-148, "Removal and Installation" or TM-88,
"Removal and Installation".

CL-26
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
2. Lock the flywheel using the tool [SST: — (Mot.1431)] (1).
A

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3. Remove three clutch cover mounting bolts at 120° intervals.
4. Replace these three bolts by the tool [SST: — (Emb.1761) (1)].
CAUTION: E
Never drop clutch disc.
5. Place the three spacers of tool [SST: — (Emb. 1761)] in contact
using the nuts. F
6. Gradually remove the six remaining bolts.

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7. NOTE:
These instructions must be respected to prevent twisting the clutch cover:
• Unscrew and gradually remove by quarter turns the three nuts of tool [SST: — (Emb. 1761)] one by one. I
8. Remove clutch cover.
9. Remove clutch disc.
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INSTALLATION
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1. In case of clutch cover re-used follow the procedure below :
NOTE:
The automatic compensation must be repositioned at its first point.
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a. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
b. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage M
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts. N
c. Place the base of tool (1) [SST: — (Emb.1604)] in a vice jaw.

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CL-27
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
d. Install clutch cover onto the base plate then the ball bearing or
bronze ring (1) and the nut (2).

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e. Tighten the nut (1) fully.

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f. Fit a circlip clamp at (1).

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g. Compress the spring (1) to reprime the automatic compensa-

tion.
h. Slacken off the nut (2) completely (spring compressed).
i. Release the clutch cover.

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j. Remove the clutch cover from the base plate of tool [SST: —
(Emb.1604)].
NOTE:
Be sure that the springs are correctly compressed.

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CL-28
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
k. Install clutch disc on flywheel using a suitable clutch aligner (A).
A

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l. Install clutch cover (2) on flywheel (1). Fit the Self Adjusting
tools (A) using 3 of the cover bolt fixing holes.
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m. Use Self Adjusting Clutch tools (A) to depress diaphram fingers H

until cover body fixing flange touches flywheel.

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n. Fit cover bolts in the 6 available holes and tighten to the speci-
fied torque. Refer to CL-26, "R9M : Exploded View" .
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o. Remove Self Adjusting Clutch tools. O

Fit bolts in the 3 remaining holes and tighten to the specified
torque. Refer to CL-26, "R9M : Exploded View" .
Remove the disc alignement tool (A). P

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CL-29
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
p. Install transaxle assembly to the vehicle. Refer to TM-88, "Removal and Installation" (2WD) or TM-148,
"Removal and Installation" (4WD).

R9M : Inspection INFOID:0000000010288581

INSPECTION AFTER REMOVAL

CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the : Refer to CL-31,

area to be measured "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.

Maximum allowable spline : Refer to CL-31,

SCL221
backlash (at outer edge of disc) "Clutch Disc".
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

Facing wear limit (depth to the : Refer to CL-31,

rivet head) "Clutch Disc".

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CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].

Tolerance for diaphragm : Refer to CL-31,

spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
rivet with a hammer. PCIB0276E

• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

CL-30
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000010288582
B

Type of clutch control Hydraulic

C
Clutch Pedal INFOID:0000000010288583

Unit: mm (in) CL
Clearance “A” between clutch pedal and ASCD switch threaded
0.2 - 1.96 (0.008 - 0.0772)
end while clutch pedal is fully released.
Clearance “B” between clutch pedal and Interlock switch threaded
0.2 - 1.96 (0.008 - 0.0772)
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end while clutch pedal is fully released.

Clutch Disc INFOID:0000000010288584

F
Unit: mm (in)

Engine type HRA2DDT K9K R9M MR20DD

Model 225 240 230
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Facing size (Outer dia. × Inner 225 × 150 × 2.9 (8.9 × 225 × 150 × 2.9 (8.9 × 239 × 170 × 3.45 (9.41 230 × 155 × 3.2
dia. × Thickness) 5.91 × 0.114) 5.91 × 0.114) × 6.69 × 0.1358) (9.06 × 6.10 × 0.126)
H
1.0 (0.039) /230 (9.06)
Runout limit/diameter of the 1.0 (0.039) /215 (8.46) 1.0 (0.039) /215 (8.46) 1.0 (0.039) /240 (9.45)
dia.
area to be measured dia. dia. dia.

Maximum allowable spline I

1.2 (0.047) 1.28 (0.0504) 0.9 (0.035)
backlash (at outer edge of disc)
Facing wear limit (depth to the
replace if worn to rivet head 0.3 (0.012)
rivet head) J

Clutch Cover INFOID:0000000010288585

K
Engine type HRA2DDT K9K MR20DD R9M
Transaxle type RS6F94R RS6F52A (4WD) RS6F95R (2WD)
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5,730 N (584.5 kg, 7,100 N (724.2 kg, 5,700 N (581.4 kg,
Set-load 8,800 N (897.6 kg, 1978.2 lb)
1,288.1 lb) 1416.2 lb) 1,281.4 lb)
Tolerance for diaphragm
spring lever unevenness
1.2 mm (0.047 in) or less not specified 0.8 mm (0.031 in) or less M

Diaphragm spring lever 12.6 - 16.2 mm 12.8 - 14.8 mm 20.7 - 22.7 (0.815 -
26.6 - 29.0 mm (1.047 - 1.142 in)
height (new clutch) (0.496 - 0.64 in) (0.504 - 0.583 in) 0.8937)
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CL-31