SECTION 7A - CLUTCH

Service Precaution

General Description

Diagnosis

Clutch Assembly

Clutch Assembly and Associated Parts

Removal

Inspection and Repair

Installation

Clutch Control

Parts Location View

Removal

Inspection and Repair

Installation

Master Cylinder

Disassembly

Inspection and Repair

Reassembly

Slave Cylinder

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Damper Cylinder

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Main Data and Specifications

Special Tools

SERVICE PRECAUTION

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN POSSIBLE

AIR BAG DEPLOYMENT, PERSONAL INJURY, OR

OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the correct

tightening sequence and specifications. Following

these instructions can help you avoid damage to

parts and systems.

GENERAL DESCRIPTION

Clutch

A07RW031

The 6VD1 (3.2L) engine with MUA manual transmission

employs a pull-type clutch.

The clutch assembly consists of the pressure plate

assembl y and the driv en pla te a ssem bly.

The clutch pedal is connected to the release bearing

through the shift fork.

The driven plate assembly is installed between the

flywheel and the pressure plate. Diaphragm spring

pressure holds the driven plate against the flywheel and

the pressure plate to provide the friction necessary to

engage the clutch.

Depressing the clutch pedal moves the shift fork against

the release bearing. The release bearing force

overcomes the force of the diaphragm spring and

separates the driven plate from the flywheel and

pressu re plate to diseng age the cl utc h.

Master Cylinder

A07RW071

The master cylinder converts mechanical energy into

hydraulic energy.

Depressing the clutch pedal causes the push rod to

move against the piston to close the return port.

Clutch fluid is forced out of the master cylinder.

Releasing the clutch pedal causes the return spring to

force the piston back to its original position.

Damper Cylinder

A07RS004

In order to reduce pulsations in the clutch hydraulic

system, a damper cylinder is used in the clutch

hydraulic line between the master cylinder and slave

cylinder.

Slave Cylinder

A07RW037

The slave cylinder converts hydraulic energy into

mechanical energy. Hydraulic fluid supplied by the

master cylinder moves the slave cylinder piston to

actuate th e shift fork. The mechani cal ene rgy pr oduced

by the slave cylinder is directly proportional to the ratio

between the diameters of the master cylinder and the

slave cylinder.

Pressure Plate Asse mbly

A07RW025

The pressure plate assembly consists of the clutch

cover, the pressure plate with diaphragm spring.

Operati ng the cl utch pedal caus es the pres sure pl ate to

move in an ax ial direc tion to en gage and di sengage th e

clutch.

Driven Plat e Assembly

A07RW027

The driven plate ass embly consi sts of the plate and the

facing.

The plate consists of the clutch center, the cushioning

plate, and the torsi on springs .

The facing is riveted to both sides of the cushioning

plate.

The cushioning plate provides a longer service life by

minimizing wear and vibration at the clutch contact

surfaces.

DIAGNOSIS

Condition Possible cause Correcti on

Dragging Air in circuit. Bleed and check for damage.

Driven plate worn or warped. Replace.

Clutch fork off the ball stud. Install correctly and lubricate.

Diaphragm spring weak or tip of

fingers worn. Replace.

Driven plate sticking on splines. Clean and free splines and lubricate

with grease.

Pilot bearing worn or damaged. Replace.

Master cylinder and slave cylinder

seals worn. Replace.

Slipping Clutch facing worn. Replac e.

Driven plate friction pads worn or

oilsoaked. Replace and check for leaks as

needed.

Diaphragm spring weak. Replace pressure plate.

Pressure plate or flywheel warped. Replace.

Master cylinder and slave cylinder

seals worn. Replace as needed.

Chattering Clutch facing in poor contact or

facing warped. Replace.

Surface of faci ng har den ed. Replac e.

Driven plate friction pads oil soaked. Replace and check for leaks.

Damper springs weakened or

broken. Replace.

Rivets on clutch plate loosened. Replace.

Pressure plate or flywheel warped. Replace as needed.

Rattling Diaphragm spring weak. Replace the pressure plate.

Clutch fork loose or off the ball stud. Replace the retaining spring or

install the fork correctly.

Driven plate springs weak or oil in

the damper. Replace and check for leaks as

needed.

Release bearing noisy with the

clutch engaged Release bearing binding. Clean, or replace if damaged, and

lubricate.

Clutch fork off the ball stud or loose

spring tension. Install correctly, and lubricate.

Linkage return springs weak. Replace.

Noisy Release bearing worn or damaged. Replace.

Clutch fork off the ball stud. Install correctly and lubricate.

Pilot bearing loose. Replace.

Pedal stays on the floor when

disengaged Replace bearing binding. Free up, or replace, and lubricate.

Diaphragm spring weak. Replace the pressure plate.

Pedal is hard to push down Hydraulic line blocked or crimped. Clean out or replace.

Master or slave cylinders bindinig. Repair or replace as needed.

Driven plate worn. Replace.

Squeaking Ball stud not lubricated or incorrectly

lubricated. Lubricate with high temperature

grease.

CLUTCH ASSEMBLY

CLUTCH ASSEMBLY AND ASSOCIATED PARTS

201RS023

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REMOVAL

1. Refer to “Manual Transmission" of Section 7B for

“Removal and Installation" procedure of the

transmission assembly (1).

Legend

(1) Transmission Assembly

(2) Press ur e Pl ate Assembly

(3) Driven Plate Assembly

(4) Release Bearing

(5) Shift Fork

(6) Fulcrum Bridge

(7) Flywheel Assembly and Crankshaft Bearing

2. Use the pilot aligner J24547 to prevent the driven

plate assembly (3) from falling free.

201RS001

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3. Mark the flywheel, clutch cover and pressure plate

lug for alignment when installing.

4. Remove the release bearing (4) from the

transmission case.

201RS024

5. Remove the snap pin. Remove the shift fork pin

and shift fork from the fulcrum bridge.

201RS025

6. Remove the fulcrum bridge bolts. Remove the

fulcrum bridge (6) from the transmission case.

201RS026

• Do not remove crankshaft spigot bearing (7)

except for replacement.

Legend

(2) Press ur e Pl ate Assembly

(3) Driven Plate Assembly

(8) Pilot Aligner

• Use the remover 5–8840–2000–0 and sliding

hammer 5–8840–0019–0 to remove the

crankshaft spigot bearing.

015RW053

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear ,

damage, or any other abnormal condition are found

through inspection.

Pressure Plate Asse mbly

• Visually check the pressure plate friction surface for

excessive wear and heat cracks. If excessive wear or

deep heat cracks are present, the pressure plate

must be replaced.

201RS002

Pressure Plate Warpage

• Use a straight edge and a feeler gauge to measure

the pressure plate friction surface flatness in four

direct ions. If any of the meas ured valu es exc eed the

specified limit, the pressure plate must be replaced.

Pressu re Pla te Wa rpage

Limit: 0.3 mm

201RS003

Clutch Cover

• Visually check the entire clutch cover for excessive

wear, cracking, and other damage. The clutch cover

must be replaced if any of these conditions are

present.

201RS004

Clutch Set Force

1. Invert the pressure plate assembly.

2. Place a new driven plate over the pressure plate.

An 8.0mm thick piece of sheet metal may be used in

place of the driven plate.

3. Compress the pressure plate assembly until the

distance (A) is12m m.

4. Note the pressure gauge reading. If the measured

value is less than the specified limit, the pressure

plate assembly must be re placed.

Clutch Set Force

Standard: 7208N

Limit: 6670N

201RW014

Diaphragm Spring Finger Height

1. Place a new driven plate or a 8.0mm spacer

beneath the pr ess ure pla t e.

2. Fully compress the pressure plate and diaphragm

spring.

There are two ways to do this:

a Use a bench press to press down on the

assembly from the top.

b Tighten the fixing bolts.

Preload on diaphragm spring finger must be 5000N in

direction of release, when clutch cover assembly is

bolted to the flywheel.

3. Measur e the spr ing he igh t fr om b ase to s pring ti p. If

the me asured value ex ceeds the specifi ed limit, the

pressure plate assembly must be replaced.

Spring Finger Height

Standard: 49.9 – 51.9 mm

201RW016

Driven Plate Assembly

• Visually check the torsion spring for looseness,

breakage, and weakening. If any of these conditions

are discovered, the driven plate assembly must be

replaced.

• Visually check the facing surfaces for cracking and

excessive scorching. Visually inspect the facing

surfaces for the presence of oil or grease. If any of

these conditions are discovered, the facing must be

cleaned or replaced.

• Check that the driven plate moves smoothly on the

transmission top gear shaft spline. Minor ridges on

the top gear s haft spline may be removed with an oil

stone.

201RS007

(A)

Driven Plat e Warpa ge

1. Insert the clutch pilot aligner J–24547 into the driven

plate splined hub. The clutch pilot aligner must be

held perfectly horizontal.

2. Set a dial indicator to the driven plate outside

circumference.

3. Slowly turn th e driven plate. Re ad the dial indi cator

as you turn the driven plate. If the m easured valu e

exceeds the specified limit, the driven plate

assembly must be replaced.

Driven Plate Warpage

Standard: 0.7mm

Limit: 1.0mm

201RS008

Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub.

2. Install the driven plate to the transmission top gear

shaft spline.

3. Set a surface gauge to the driven plate outside

circumference.

4. Slowly turn the driven plate counterclockwise.

Measure the spline rotation play as you turn the

driven plate. If the measured value exceeds the

specified limit, the driven plate assembly must be

replaced.

Driven Plate Warpage

Standard: 0.5mm

Limit: 1.0mm

201RS009

Rivet Head Depression

• Use a depth gauge or a straight edge with steel rule

to measure the rivet head depression (1) from the

facing surface (2).

• Be sure to measure the rivet head depression on

both sides of the driven pl ate. If the measu red value

is less than the specified limit, the driven plate

assembly must be replaced.

Rivet Head Depression

201RS010

Standard Limit

Fly wheel side 1.2–1.8mm 0.2mm

Pressure plate

side 1.6–2.2mm

Release Bea ri ng

• V isually check the release bearing for excessive play,

noise a nd br eakag e. I f any of thes e con ditions are

discovered, the release bearing must be replaced.

201RS011

• When replacin g the releas e bearing (4), rep lace both

the wedge collar (10) and wire ring (11) at the same

time.

201RS012

EndOFCallout

Wedge Collar (10)

• Visually check the surfaces of the wedge collar

making contact with the release bearing for excessive

wear and damage .

• Replace exhibiting excessive wear or damage.

201RS013

Shift Fork

• Visually check the surfaces of the shift fork making

contact with the release bearing for excessive wear

and damage.

• Remove any minor stepping or abrasion from shift

fork with an oil stone. Replace exhibiting excessive

wear or damage.

201RS014

Legend

(2) Press ur e Pl ate Assembly

(4) Release Bearing

(10) Wedge collar

(11) Wire Ring

INSTALLATION

1. Clean and lubricate with grease.

2. Use the installer 5–88 40–0125–0 and driver han dle

5–8840–0007–0 to install the crankshaft spigot

bearing (7).

015RW054

3. Install the fulcrum bridge (6) to the transmission

case. Tighten three fulcrum bridge bolts to the

specified torque.

Torque: 38 Nm

201RS026

4. Apply molybdenum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.

Attach the shift fork (5) to the fulcrum bridge (6) and

insert the pin from below of the fulcrum bridge.

Install the washer and snap pin.

201RS018

5. Apply molybdenum disulphide type grease to the

areas shown in the figure.

201RW012

Install the release bearing (4) in the correct

direction.

NOTE: Ensure release bearing is properly positioned

during installation, as shown in the figure.

201RS019

6. Use the pilot aligner 5–85253–001–0 to install the

driven plate assembly (3).

201RX004

7. Tighten the bolts holding the pressure plate

assembly (2) in the order shown in the figure.

201RS017

Torque: 18 Nm

8. Remove the aligner.

Do not strike the aligner with a hammer to remove it.

9. Install transmission assembly to the engine.

CLUTCH CONTROL

PARTS LOCATION VIEW

203R100001

EndOFCallout

Legend

(1) Master Cylinder Assembly

(2) Pedal Assembly

(3) Pin and Jaw Joint Pin

(4) Oil Line Pipe and Hose

(5) Slave Cylinder Assembly

(6) Damper Cylinder Assembly

REMOVAL

1. Disconnect the ground battery cable.

2. Remove the instrument panel lower cover (7) and

driver knee bolster panel assembly (8).

740RW162

EndOFCallout

3. Remove pin and jaw joint pin (3).

4. Remove pedal assembly (2).

5. Remove oil line pipe (4).

6. Remove slave cylinder assembly (5).

7. Remove master cylinder assembly (1).

8. Remove damper cylinder assembly (6).

9. Remove oil line hose (5).

INSPECTION AND REPAIR

Make necessary adjustments, repairs, and part

replacements if wear, damage or other problems are

discovered during inspection.

INSTALLATION

Clutch Pedal Adjustment

208RX004

EndOFCallout

1. Loosen clutch master cylinder push rod lock nut.

Turn push rod by hand to set clutch pedal height to

within specification. Tighten push rod lock nut.

Clutch Pedal Height

178 – 188 mm (7.01 – 7.40 in)

F07RW026

2. For vehicles with cruise control, refer to Section 12 -

Cruise Control for clutch switch adjustment.

F07RW027

Legend

(7) Driver Lower Cover

(8) Driver Knee Bolster Panel

Legend

(7) Push Rod

3. After adjusting the clutch pedal height, push the

clutch ped al b y ha nd to ens ure the cl utch ped al fre e

play is within specification.

Pedal Free Pla y

5 – 15 mm

4. Perform clutch pedal engagement height inspection:

1. Operate the parking brake lever and block the

wheels.

2. Start the engine, fully step on the clutch pedal

slowly and move the shift lever 1st position.

3. With the engine idling, release the clutch pedal

slowly and measure its stroke - just prior to its

clutching position.

Clutch Pedal Engagement Height (H3)

MIN. 30 mm

F07RW028

5. If the measured value exceeds the specified limit,

check the following points and repair if necessary:

• Hydraulic circuit for fluid leakage or air in circuit.

• Clutch disc warped.

• Diaphragm spring weakened or tip of fingers

worn.

• Driven plate sticking on sprines.

• Release bearing worn or damaged.

• Master cylinder and slave cylinder worn.

Torque

•Master cylinder to dash panel

16 N·m

•Clutch pedal to dash panel

15 N·m

•Master cylinder push rod to yoke

17 N·m

•Clutch pipe to master cylinder

20 N·m )

•Clutch pipe to damper cylinder

12 N·m

•Clutch pipe to flex, hose

20 N·m

•Flexible hose to slave cylinder

20 N·m

•Slave cylinder to case

40 N·m

•Slave cylinder bleeder screw

8 N·m

Bleeding

1. Check the level of clutch fluid in the reservoir and

replenish if necessary.

2. Bleedi ng the sl ave cyl inder.

1. Remove the rubber cap from the bleeder screw

and wipe clean the bleeder screw. Connect a

vinyl tube to the bleeder screw and insert the

other end of the vinyl tube into a transparent

container.

2. Pump the clutch pedal repeatedly and hold it

depressed.

203RS005

3. Loosen th e bleed er scr ew to relea se cl utch flui d

with air bubbles into the container, then tighten

the bleeder screw immediately.

4. Release the clutch pedal carefully. Repeat the

above operation until air bubbles disappear from

the clutch fluid being pumped out into the

container. During the bleeding operation, keep

the clutch fluid reservoir filled to the specified

level. Reinstall the rubber cap.

MASTER CYLINDER

208RX003

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DISASSEMBLY

1. Disassemble reservoir cap (1), inner cap (2), seal

(3), clip (5), and reservoir (4).

2. Disassembly gasket (7), yoke (9), nut (8) and body

sub assembly.

INSPECTION AND REPAIR

Make the necessary adjustments, repair, and part

replacements if excessive wear or damage is

discovered during inspection.

REASSEMBLY

To reassemble, follow the disassembly steps in the

reverse or der.

Legend

(1) Reservoir Cap

(2) Inner Cap

(3) Seal

(4) Reservoir

(5) Clip

(6) Body Sub Assembly

(7) Gasket

(8) Nut

(9) Yoke

SLAVE CYLINDER

DISASSEMBLED VIEW

206RS002

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DISASSEMBLY

1. Disassemble boot (1), push rod (2), piston and

piston cup (3), and spring (4) from cylinder body (5).

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is

discovered during inspection.

Cylinder Body

1. Clean the cylinder body.

2. Chec k the fluid return port for rest rictions and clea n

it if necessary.

206RS003

Legend

(1) Push Rod

(2) Boot

(3) Piston and Piston Cup

(4) Spring

(5) Cyli n de r Bo d y

Piston and Piston Cup

1. Visually inspect the disassembled piston and piston

cup for excessive wear and damage.

206RS004

Replace the inner parts with new parts if necessary.

2. Measure the clearance between slave cylinder wall

and piston.

206RS005

If the measured value exceeds the specified limit,

the slave cylinder assembly must be replaced.

Standard: 0.07 mm (0.0028 in)

Limit: 0.15 mm (0.0059 in)

REASSEMBLY

To reassemble, follow the disassembly steps in the

reverse or der, noting the following points:

Piston Assembly

1. Before installing the parts, apply a thin coat of

rubber grease.

2. Install cup in groove in piston with the lip turned to

the front o f cylinder. Us e care so as n ot to scratch

the cylinder.

206RS006

DAMPER CYLINDER

DISASSEMBLED VIEW

205RW005

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DISASSEMBLY

1. Disassembly cover and gasket (6).

2. Disassembly damper rubber (5).

3. Disassembly spacer (4).

4. Disassembly piston assembly (3).

5. Disassembly spring (2).

6. Disassembly cylinder body (1).

INSPECTION AND REPAIR

Check damper rubber and piston cup for cracks,

deformation or damage.

Replace the damper cylinder assembly if necessary.

REASSEMBLY

To assemble, follow the disassembly steps in the

reverse or der.

Legend

(1) Cylinder Body

(2) Spring

(3) Piston Assembly

(4) Spacer

(5) Damper Rubber

(6) Cover and Gasket

MAIN DATA AND SPECIFICATIONS

General Specifications

Torque Specifications

E07RX020

Engine 6VD1

Type Dry single plate type with diaphragm spring

Size 260 mm

Pressure plate

Outside diameter 332 mm

Clamping force 7208 N

Spring finger height 49.9 – 51.9 mm

Driven plate

Outside diameter × inside diameter 260 × 170 mm

Thickness

Clutch disengaged 8.6 mm

Clutch engaged 8.0 mm

Total friction area 304 × 2 cm2

Clutch control type Hydraulic

Clutch pedal free play 5 – 15 mm

Clutch pedal stroke 165.5 –175.5 mm

Clutch pedal height 178 – 188 mm

203R100002

SPECIAL TOOLS

ILLUSTRATION PART NO.

PART NAME

5–85253–001–0

Driven plate aligner

(6VD1)

5–8840–2000–0

5–8840–0019–0

Pilot bearing remover and

Sliding hammer

5–8840–0013–0

Bearing puller

5–8840–0124–0

Adapter

5–8840–0007–0

Crankshaft pilot bearing

installe r (6 VD 1 )

5–8840–0007–0

Driver hand le