Kia Pride 1994 1995 1996 Workshop Repair Service Manual

Clutch System General Information

Clutch System

1994 > 1.3L SOHC >

DESCRIPTION AND OPERATION • When the clutch pedal is pressed, the cable and release lever rotate a shaft that enters the transaxle clutch housing and connects to the clutch release fork.

• As the shaft rotates, the fork slides the release bearing along the transaxle bearing support until it contacts and releases the pressure plate.

• When the pedal is released, springs attached to the support bracket and release lever return the clutch release components to the normal applied position.

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1994 > 1.3L SOHC >

TROUBLESHOOTING GUIDE Trouble

Slippage

Possible cause

Remedy

Facing worn excessively

Replace

Facing surface hardened or contaminated with oil

Repair or replace

Clutch cover deformed

Repair or replace

Diaphragm spring damaged or fatigued

Replace

Excessive clutch pedal play

Adjust

Clutch pedal not functioning smoothly

Repair or replace

Flywheel warped

Repair or replace

Clutch pedal not functioning smoothly

Replace

Excessive deflection and deformity of clutch disc Replace

Poor disengagement

Clutch judders when engaging

Clutch pedal does not function smoothly

Nosie

Clutch disc spline worn or rusted

Replace or remove the rust

Oil on the facing surface

Clean or replace

Diaphragm spring fatigued

Replace

Excessive clutch pedal play

Adjust

Oil an facing surface

Clean or replace

Torsion spring fatigued

Replace

Facing surface hardened or deformed

Repair or replace

Facing rivets loose

Replace

Diaphrgm spring fatigued

Replace

Clutch cover excessively warped

Replace

Flywheel surface hardened or warped

Repair or replace

Engine mount loose or fatigued

Refer to EM

Pedal shaft not properly lubricated

Lubricate or replace

Cable not properly lubricated

Lubricate or replace

Cable kinked

Repair or replace

Release bearing damaged

Replace

Poor lubrication of release bearing sleeve

Lubricate or replace

Worn sliding part of release fork

Replace

Torsion spring fatigued

Replace

Pedal freeplay insufficiend

Adjust

Excessive crankshaft end play

Refer to EM

1994 > 1.3L SOHC >

Engine Type

Item

B3 Engine

B5 Engine

Clutch control type Clutch cover

Clutch disc

Cable

Type

Diaphragm spring

Set load

3,276 kgf (334N, 735 lb)

Outer diameter

180 mm (7.087 in)

200 mm (7.87 in)

Inner diameter

125 mm (4.921 in)

130 mm(5.12 in)

Pressure plate side

3.2 mm (0.126 in)

3.8 mm (0.150 in)

Flywheel side

3.0 mm (0.116 in)

3.5 mm (0.138 in)

Thickness Type Clutch pedal

3,630 kgf (370N, 814 lb)

Pedal ratio Full stroke Height

Suspended 5.81 : 1

6.40 : 1 74 mm (2.92 in) 205 mm (8.075 in)

Clutch System Clutch System - Clutch Cover and Dinode

Clutch System

1994 > 1.3L SOHC >

REMOVAL

Do note allow an oil or grease to contaminate the clutch disc facing. Even trace of oil or grease may cause clutch grabbing or slipping. Handle the disc by its edges and do not touch the facing.

1. Remove the transaxle.

2. If the pressure plate will be reused, paint or scribe the alignment marks on the pressure plate and flywheel for assembly reference.

Loosen the pressure plate bolts one turn at a time to release the pressure plate spring tension evenly. A failure to release the tension evenly could cause distortion of the pressure plate.

3. Remove the pressure plate blots, the pressure plate, and the clutch disc. While loosening the blots, use Flywheel Holding Tool to prevent turning of the flywheel.

FLYWHEEL 1. Remove the transaxle.

2. Remove the clutch pressure plate and disc. Refer to the procedure in this section.

While loosening the bolts, use a Flywheel Holding Tool to prevent the flywheel from turning.

3. Remove the pressure plate bolts and the flywheel.

PILOT BEARING 1. Remove the flywheel. Refer to the procedure in this section.

2. Use a suitable driver to remove the pilot bearing from the flywheel.

INSTALLATION 1. Position the clutch disc on the flywheel and hold it in position with a Clutch Aligner.

Use the marks, which are made during the removal for the alignment reference.

2. Position the pressure plate on the flywheel and install the pressure plate bolts.

Tighten the bolts evenly and alternately to prevent distortion of the pressure plate.

3. Tighten the pressure plate bolts.

Tightening torque : 18 ~ 26 N·m (1.8 ~ 2.6 kg·m, 13 ~ 20 lb·ft) 4. Remove the clutch alignment tool.

Before installing the transaxle, clean the clutch disc splines on the input shaft and coat them with a light film of a Clutch Grease, or equivalent.

5. Install the transaxle.

FLYWHEEL 1. Clean the sealant from the flywheel bolts.

2. Coat the six flywheel bolt threads with a stud and Bearing Mount Sealer, or equivalent.

3. Position the flywheel on the crankshaft and install the six flywheel bolts. Use the Flywheel Holding Tool to prevent the flywheel from turning.

4. Tighten the six flywheel bolts.

Tightening torque : 96 ~ 103 N·m (9.6 ~ 10.3 kg·m, 71 ~ 76 lb·ft)

5. If the flywheel has been replaced, it will be necessary to install a pilot bearing in the new flywheel. Refer to the procedure in this section.

PILOT BEARING

Make sure the driver contacts the bearing outer race. Any contact to the inner race will damage the bearing.

1. Install the pilot bearing using a suitable driver.

2. Install the flywheel. Refer to the procedures in this section.

INSPECTION CLUTCH COVER 1. Check the contact surface of the clutch disc for scorings, cracks, or discoloration.

Minor scoring or discoloration should be removed with sandpaper.

2. Inspect the diaphragm spring for damage, or damage to the cover.

CLUTCH DISC 1. Check the facing surface for hardening or oil contamination.

Use sandpaper if the trouble is minor.

2. Inspect the looseness of the facing rivets.

3. Worn of the clutch disc. Measure the depth to the rivet heads with a slide caliper.

Depth : 0.3 mm (0.012 in) min.

4. Inspect the run-out of a clutch disc.

Lateral run-out : 0.7 mm (0.027 in) max.

Vertical run-out : 1.0 mm (0.039 in) max.

5. Inspect the wear or rust on the splines. Remove any minor rust.

FLYWHEEL 1. Surface cracks scoring or, discoloration of clutch contact surface.

If the problem is minor, the repairs can be made by cleaning with sandpaper.

2. Damaged or worn ring gear teeth.

If necessary, replace the ring gear as follows : (1) Heat the ring gear with a blowtorch, then tap around the gear to remove it from the flywheel.

(2) Heat the new ring gear to 250 ~ 300C (480 ~ 570F), then fit it onto the flywheel.

The beveled side of the ring gear must face toward the engine side.

3. Run-out of flywheel (1) To measure, position the dial gauge feeler on the clutch disc contact surface, then turn the flywheel.

Run - out : 0.2 mm (0.008 in) max.

(2) If the run-out exceeds the specification, repair by grinding.

Grinding limit : 0.5 mm (0.020 in) max.

Clutch System Clutch System - Clutch Pedal

Clutch System

1994 > 1.3L SOHC >

COMPONENTS

1994 > 1.3L SOHC >

ADJUSTMENT PEDAL HEIGHT 1. Disconnect the clutch cable at the transaxle release lever to eliminate the possibility that the clutch cable is affecting pedal height.

2. Measure the distance from the upper center of the pedal pad to the dash lower panel and ensure the distance is within the specification.

Pedal height : (WITHOUT CARPET) 205 mm (0.8075 in) 3. Inspect the clutch pedal mounting for damaged, worn, or missing parts.

4. To adjust the pedal height, loosen the lock nut and turn the clutch switch until the lower pedal is at the specified height.

5. Tighten the lock nut.

Tightening torque : 14 ~ 18 N·m (1.4 ~ 1.8 kg·m, 10 ~ 13 lb·ft)

PEDAL FREEPLAY 1. Depress the pedal lightly by hand and measure the freeplay, and ensure that it is within the specification.

Pedal freeplay : 9 ~ 15 mm (0.35 ~ 0.59 in) 2. Depress the release lever and pull the pin away from the lever, then adjust the clearance by turning the adjust nut.

Standard clearance : 1.5 ~ 2.5 mm (0.06 ~ 0.10 in)

3. After the adjustment ensures that when the clutch is disengaged, the distance between the dash lower panel and the upper center of the pedal pad is within the specification.

Disengagement height : 74 mm (2.92 in) min.

REMOVAL CLUTCH CABLE 1. Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lover.

2. Remove the bolts attaching the cable routing bracket to the transaxle.

3. Remove the clip which is securing the cable case to the pedal support bracket.

4. Pull upward on the cable and disengage it from the hook on the pedal.

5. If necessary, loosen the attaching nut and remove the routing bracket.

6. Remove the cable through the hole in the bulkhead.

CLUTCH PEDAL 1. Loosen the cable adjuster nut at the transaxle release lever until the cable can be disengaged from the lever.

2. Remove the clip securing the cable case to the pedal support bracket.

3. Pull upward on the cable and disengage it from the hook on the pedal.

4. Remove the attaching nut, lock washer, and flat washer from the end of the pivot bolt.

5. Slide off the clutch pedal and return spring from the pivot bolt.

6. If necessary, remove the pedal pad, stop bumper, and bushings from the pedal.

Apply grease (lithium base, NGLI No. 2) to the bushings and pivot points.

INSTALLATION CLUTCH CABLE CLUTCH PEDAL INSPECTION CLUTCH CABLE 1. Worn or damaged bushings.

2. Twisted or bent clutch pedal.

3. Worn or damaged pedal pad.

4. Damage to the inner or outer cable.

5. Function of the cable.

Clutch System Clutch System - Clutch Release Cylinder

Clutch System

1994 > 1.3L SOHC >

REMOVAL 1. Remove the transaxle. Refer to Section 41.

2. Remove the release fork attaching bolt.

3. Remove the release bearing.

RELEASE FORK / LEVER 1. Remove the transaxle. Refer to Section 41.

2. Remove the release fork attaching bolt.

3. Remove the release bearing.

4. Remove the release lever return spring.

5. Slide the release lever upward out of the release fork and remove the fork.

6. Slide the release lever out of the transaxle clutch housing.

7. Remove the release lever bushings from the transaxle clutch housing.

INSTALLTION 1. Apply a light film of Lubricant XG-1-C, or equivalent, on the following areas : A. The sliding surface on the transaxle bearing support B. The release fork where it contacts the bearing C. The front of the bearing where the pressure plate release spring contacts.

Fill only the groove and remove all the excess grease from the bearing hub. If the excess grease remains in the hub, it can be forced onto the clutch disc splines where it may contaminate the clutch friction surfaces.

2. Fill the groove in the release bearing hub with a Lubricant XG-1-C, or equivalent. Also, apply a light film of lubricanton the release fork contact area. The lubricant areas are shown in the right illustration.

3. Install the release bearing.

4. Install the release fork attaching bolt. Tighten the attaching bolt.

Tightening torque : 35 ~ 41 N·m (3.6 ~ 4.2 kg·m, 26 ~ 30 lb·ft)

5. Install the transaxle. Refer to Section 41.

RELEASE FORK/LEVER

Apply a light film of Lubricant XG-1-C, or equivalent, to the inside of the bushing before installing.

1. Install the release lever bushings.

2. Install the release bearing. Refer to the Release Bearing installation procedure for the proper lubrication of the bearing.

3. Position the release fork and install the release lever.

4. Install the release lever return spring.

5. Align the boltholes in the release fork and lever shaft.

6. Install the release fork attaching bolt and tighten.

Tightening torque : 35 ~ 41 N·m (3.5 ~ 4.1 kg·m, 26 ~ 30 lb·ft)

7. Install the transaxle.

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