SECTION 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY

4.bolt(S)

6.Main clutch

7.Clutch disc

8.Clutch cover

9.Pin(B)

12.Input metal

13.Seal bolt

14.Nut

15.Washer spring

18.Metal sleeve

19.Seal bolt

20.O-ring

21.Sleeve

22.Clutch release bearing

23.Tension spring

1.MAIN CLUTCH

1-1.Disassembly

Note:

Generally it is impossible to separate diaphragm spring type clutch cover.

It is principle to replace the clutch with assembly if pressure plate,diaphragm spring are needed to be replaced.

1) DISASSEMBLY

Separate the engine from the front transmission referring to the paragraph "SEPARATION OF MAJOR COMPONENT in chapter 2.“

2) Remove the clutch assembly from the flywheel.

Note:

When removing the bolts,loosen them gradually in diagonal sequence.

Take care not to let oil get on the clutch facing.

1-2.Inspection of the clutch disc.

Install the disc on the input gear and inspect the rotation play.If the measurement deviates from the specified value,Replace the disc.

1) Inspect the diaphragm spring surface for up-and-down,scratches,stepped wear,or oil stains.

2) Check the height differences of diaphragm springs.

3) If damage is found on the pressure plate. The clutch cover must be replaced.

4) Shallow scratches may be repaired with a sand paper,but excessive wear or damage must be replaced.

1-5.Inspection of guide ball bearing (flywheel)

1. If the bearing does not turn smoothly due to damage or seizure,replace the bearing.

1-6.Reassembly of main clutch

Reassemble them in reverse order of disassembly in accordance with the following instructions.

1) Be sure to keep oil off of the clutch disc,the pressure plate,and the flywheel.

2) Apply a thin coat of molybdenum disulfide-based grease to resolving or sliding parts prior to reassembly.

3) When installing the clutch disc on the flywheel,turn the longer protrusion of the hub towards the flywheel.The reverse installation will damage the clutch cover or the disc.When installing the dual clutch assembly,use a special tool.

Note: Tighten the bolts with specified Torque.

Note:

The causes of oil stains must be located and necessary corrective measures must be taken.

1-4.

1) Inspect the pressure plate friction surface for up-and-down,scratches,stepped wear,or oil stains.

2) Measure the deviations of pressure plate.If the measurements are beyond the usable limits,replace the pressure plate.

3) If Wearing only outside but inside of diameter is within usable limits,replace regardless clearance.

4) The dimension between flywheel surface ⓐ and clutch face is 36.0 ±1.0 (P type), 35.0 ±1.0 (IP type). And needless to adjust.

2.CLUTCH SHAFT AND RELATED PARTS.

1) disassembly

(1) Remove the tension spring and extract the sleeve

(2) Remove the wire which is retaining the taper pin.

(2)Inspection of sleeve

Ensure smooth movement of the sleeve.If it does not move smoothly,clean and grease it. Use heat-proof grease.

(3) Inspection of tension springs. If there are some broken tension springs, replace them.

(4) Inspection of the fork. Inspect the contact faces of the fork and the sleeve.If there is abnormal wear,make repairs or replace the fork or the sleeve.

(5) Inspection of the clutch shaft. The clutch shaft must be revolve smoothly

3) Reassembly

Reassemble the disassembled parts in reverse order of disassembly,pursuant to the following instructions.

①Clutch shaft comp ②Release fork

③Taper pin ④Wire ⑤Grease fitting

Fig4-8 Main clutch and related parts

(3)Remove the grease fittings from the clutch shaft ends.

(4)Turn the release fork upward and pull out the taper pin.Then draw the clutch shaft.

2) Inspection (1)Inspection of release bearing

The release bearing is of the grease-sealed type,but when the grease in the bearing reaches a low level or the bearing does not turn smoothly due to damage or seizure, replace the bearing. Note:

The release bearing should not be washed.

(1) Each sliding part should be coated with heat-proof grease.

(2) The clutch fork taper pin should be locked securely with wire.

(3) Smooth movement of each part should be conformed.

(4) The release bearing must be installed in the correct direction.

Clutch pedal play

1) Loosen the lock nuts on the clutch rod and adjust the clutch rod length to achieve 20∼30㎜ (0.79∼1.18 in.) pedal play.Retighten the lock nut securely.

Note:

One lock nut has a right hand thread and the other has left-hand threads,so take care not to interchange them.

2) Adjust the clearance between the safety switch and the bolt head to 38 ±1㎜(1.496 in.) so that the switch will turn on only when the clutch is disengaged to allow the engine to start.

3) Inspect the clutch action.

-Inspection of clutch action and slippage. While the engine is running,the transmission gears must be shifted smoothly with the brakes applied.

-Inspection of clutch slippage

While accelerating the engine gradually, the engine must stop when the clutch is engaged gradually with the parking brakes applied and the speed shift levers to 4X4.

Note: Adjust the turnbuckle through the opening in the panel with the rubber cap removed.