SECTION 7C - CLUTCH

1. GENERAL DESCRIPTION

2. DIAGNOSIS

3. ON-VEHICLE SERVICE

3.1 CLUTCH CABLE

Removal

Inspection

Installation

3.2 CLUTCH PEDAL AND CLUTCH PEDAL

BRACKET

Clutch Pedal Height

Clutch Pedal Free Travel

4. UNIT REPAIR OVERHAUL

4.1 CLUTCH COVER, CLUTCH DISC AND

FLYWHEEL

Removal

Inspection

Installation

4.2 CLUTCH RELEASE SYSTEM

Removal

Inspection

Installation

5. REQUIRED SERVICE MATERIAL

6. SPECIAL TOOLS

WARNING:

For vehicles equipped with Supplementary Restraint (Airbag) System:

• Service on and around the airbag system components or wiring must be performed only by an

authorised HOLDEN retailer. Refer to AIRBAG SYSTEM COMPONENTS and WIRING LOCATION

VIEW under GENERAL DESCRIPTION in Section 10B AIRBAG SYSTEM in order to confirm

whether you are performing service on or near the airbag system components or wiring. Please

observe all WARNINGS and SERVICE PRECAUTIONS under ON-VEHICLE SERVICE in Section

10B AIRBAG SYSTEM before performing service on or around the airbag system components or

wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could

render the system inoperative. Either of these two conditions may result in severe injury.

• Technical service work must be started at least 90 seconds after the ignition switch is turned to

the “LOCK” position and the negative cable is disconnected from the battery. Otherwise, the sys-

tem may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

Techline

1. GENERAL DESCRIPTION

A dry single disc, diaphragm-spring clutch is fitted. The clutch disc incorpor ates four torsional coil springs and

is positioned on the spl ined transaxle input shaft.

The clutch cover, w hich is secured to the fl ywh eel, suppor ts the tapered-finger diaphragm spring. While the

clutch release bearing is not engaged, the peripheral part of the spring holds the pressure plate under ten-

sion, secur ing the clutch disc to the flywheel. This is the engaged condition of the clutch.

Depressing the clutch pedal causes the release bearing to advance and push on the diaphragm spring

tapered fingers. The diaphragm spring pulls the pressure plate away from the clutch disc, allowing the fly-

wheel to spin independent ly of the clutch disc, disengagi ng dr ive to the transaxle.

Legend

1. Crankshaft 5. Clutch cover 9. Input shaft

2. Flywheel 6. Diaphragm spr ing 10. Release shaft

3. Clutch disc 7. Release bearing

4. Pressure plate 8. Input shaft bearing

2. DIAGNOSIS

Condition Possible Cause Correction

Slipping Incorrect clutch pedal free travel Adjust free travel.

Worn or oily clutch disc facing Replace disc.

Wa rped disc, pressure plate or flywheel surface Re place disc, clutch cover o r

flywheel.

Weakened diaphragm spring Replace clutch cov er.

Rusted clutch cable Replace cable.

Dragging clutch Incorrect clutch pedal free travel Adjust free tra vel.

Weakened diaphragm spring, or worn spring tip Replace clutch cover.

Rusted input shaft splines Lubricate.

Damaged or worn splin es of tra nsaxle input shaft Re place input shaft.

Wa rped c lutch disc Replace disc .

Clutch fac ings broken or dirty with oil Re place disc.

Clutch vibration Glazed (glass-like) clutch fa cings Repair or replace disc.

Clutch fac ings dirty with oil Re place disc.

Release bearing binds on input shaft bearing

retainer Lubri ca te or replace input

shaft bearing retainer.

Wa rped c lutch disc, or poor facing contact Re place disc.

Weakened torsion springs in clutch disc Replace disc.

Clutch d isc rivets loose Replace disc.

Distor ted pres sure plate or flywheel surfac e Re place clutch cover or f ly-

wheel.

Weakened engine m ount or loose engine mou nting

bolt or nut Retighten or replace mount.

Noisy clutch Worn or broken release bearing Replace release bearing.

Input shaft front bearing worn Replace input sh aft beari ng.

Excessive rattle of clutch disc hub Replace disc .

Cracked clutch disc Replace disc.

Pressure plate and diaphragm sprin g rattling Replace c lutch cover.

Grabbing clutch Clutch disc facings soaked with oil Replace disc.

Clutch disc f a cings excessively worn Replace disc.

Riv et heads standing out from f acing Replace disc.

Weakened torsion springs Replace disc .

3. ON-VEHICLE SERVICE

3.1 CLUTCH CABLE

Legend

REMOVAL

1. Disconnect the negative cable at battery.

2. Remov e the clutch cab l e joint nut (1).

3. Remove the joint pin (2) fr om the clutch release

lever (3).

1. Clutch cable 7. Adj usting bolt

2. Release leve r 8. Lock nut

3. Joint pin

: Apply Lithium grease to joint pin. 9. Clutch cable hook

: Apply Lithium grease to cable

hook.

4. Joint nut

5. Clutch pedal Tighteni ng torque

6. Pedal bracket

4. Disconnect the cab le hook (1) from the clutch

pedal (4).

5. Remove the clutch cable (3) from the bracket (5) by

tur ning the cable cap (2 ) about 90° as shown.

INSPECTION

Inspect the clutch cable and replace it i f any of the following

conditions exist:

• Excess ive cable frict i on

• Frayed cable

• Bent or kinked cable

• Broken boots

• Worn end

INSTALLATION

1. Apply grease to the cable end hook and joint pin before

installing cable.

(A): Lithium grease

2. From inside the cabin, hook the cable end onto the

pedal busing a screwdrive r or long nose pliers.

3. Join the inner cable wire joint pin in the release lever.

4. Install the clutch cable (2) to the b racket (3 ) by tur ning

the cable cap (1) about 90° as shown.

5. Screw in the joint nut and adjust the free travel of the

pedal to specification by turnin g nut.

6. Check the clutch for proper function with the engine

running.

NOTE: Ensure that the cable grommet (4) is installed in

the correct orientation as shown.

3.2 CLUTCH PEDAL AND CLUTCH PEDAL BRACKET

Legend

CLUTCH PEDAL HEIGHT

Adj ust the clu tch ped al (1) he ight with t he adj usting bolt (2)

located on the pedal bracket (3) so that the clutch pedal

height is same as the brake pedal (4) height.

1. Clut ch cable hook

: Apply Lithium grease to

cable hook.

7. Pedal spring

: Apply Lithium grease to

inside of spring.

11. Pedal pad

12. Pedal retu rn cushion

13. Adjusting bolt cap

2. Clutch pedal bracket 8. Pedal shaft spacer

: Apply Lithium grease to

outside of spacer.

14. Adjusting bolt

3. Bolt 15. L ock nut

4. Nut Tightening torque

5. Pedal shaf t nut 9. Pedal shaft

6. Pedal bush 10. Clutch pedal

HEIGHT DIFFERENCE (a) 0 mm

CLUTCH PEDAL FREE TRAVEL

1. Confir m that t he cl utch pedal heig ht is wi thin spec ifica-

tion.

2. Depress the clutch pedal (1), stop the moment clutch

resistance is felt and measure the distance (clutch

pedal free travel).

Free travel should be within th e following specification.

3. If the free travel is out of specificat ion, adjust it with the

cable joint nut (1).

4. After checking clutch pedal free travel, also check the

clutch f or correct function with the engine running.

PEDAL FREE TRAVEL (b) 15 - 20 mm

RELEASE LEVER FREE TRAVEL (c) 0 - 2 mm

4. UNIT REPAIR OVERHAUL

4.1 CLUTCH COVER, CLUTCH DISC AND FLYWHEEL

Legend

REMOVAL

1. Remove the transaxle assembly, refer to Section 7A,

MANUAL TRANSAXLE.

2. Hold the flywheel stationary with special tool 09924-

17811 (A) and remove the clutch cover bolts (1), clutch

cover (2) and clutch disc.

1. Flywheel 7. Release bearing

2. Clutch release shaft seal

: Apply Lithium grease to seal lip. : Apply Lithium grease to bear ing

joint, release shaft and inside bearing .

3. Clutch release shaft No.2 bush

: Apply Lithium grease inside bush. 8. Clutch cover

9. Clutch disc

4. Return spring 10. Clutch cov er bolt

5. Clutch release shaft

Apply Lithium grease to the end of

release shaft arm.

11. Flywheel bolt: Apply sealant Three Bond

No. 1215 to thread.

Tightening torque

6. C lutch release shaft No.1 bush

: Apply Lithium grease inside bush. Do not reuse.

3. Withdraw the input shaft bea ring (1) using special tool

09921-26020 (B), and a wrench.

INSPECTION

Input Shaft Bearing

Check the bearing (1) for smooth rotation. Replace it if

abnormality is f ound.

Clutch Disc

Measure the depth of the rivet head depression, i.e. dis-

tance between rivet head and facing surface.

If depth is fou nd to have reached ser vice limit at any hole,

replace the disc asse mbly.

Clutch Cover

1. Check the diaphragm spring (1) for abnormal wear or

damage.

2. Inspect the pressure plate (2) for wear or heat spots.

3. If abnormality is found, replace it as an assembly. Do

not disassem ble it.

Flywheel

Check the surface contacting the clutch disc for abnormal

wear or heat spots. Replace or repair as required.

RIVET HEAT DEPTH: STANDARD

SERVICE LIMIT 1.65 - 2.25 mm

0.5 mm

INSTALLATION

NOTE: Before assembling, ensure that the flywheel sur-

face and pressure plate surface have been cleaned and

dried thoroughly.

1. Install the flywheel (1) to the crankshaft using special

tool 09924-17811 (A).

2. Apply sealant Three Bond No. 1215 to the bolts (2) and

tighten to specification.

3. Using special tool 09925-98210 (B), install the input

shaft bearing to the flywheel.

4. Align the clutch disc to the flywheel centre using

special tool 09923-36320 (C).

5. Install the clutch cover (1) and bolts. Then tighten bolts

to specification.

NOTE 1: While tightening the clutch cover bolts,

depress the clutch disc using the special tool (C) by

hand to ensure the disc remains centred.

NOTE 2: Tighten the cover bolts in small amounts

evenly, in diagonal order.

6. Apply a small amount of grease to the input shaft (1).

(A): Lithium grease

7. Install the transaxle assembly onto the engine. Refer to

Section 7A, MANUAL TRANSAXLE.

NOTE: Wh en ins erting the transaxl e inpu t sh aft onto

the clutch disc, rotate the crankshaft to align the

splines.

FLYWHEEL BOLT (a)

TORQUE SPECIFICATION 70 Nm

CLUTCH CO VER BOLT TORQUE

SPECIFICATION (b) 23 Nm

4.2 CLUTCH RELEASE SYSTEM

REMOVAL

1. Remove the release lever by loo se ning its bolt.

2. Remove the release bearing by turning the release

shaft (1).

3. Unhook the return spring by using pliers.

4. Drive out the No.2 bush by using special tool 09922-

46010 (A) and a hammer.

The re lease sh aft seal w ill also be pus hed out .

5. Remove the release shaft and return spri ng.

6. Insert a tap (M16 X 1.5) (1) into t he clutch release shaft

No.1 bush.

7. Withdraw the No.1 bush by using the tap (1) and

specia l tools 09923-46020 (B) and 09930-30104 (C).

INSPECTION

Clutch Release Bearing

Check the clutch release bearing for smooth rotation.

If abnormal ity is found , replace the beari ng.

CAUTION: Do not wash the release bearing. Washing

may cause grease leakage and consequential bear-

ing damage.

Clutch Release Shaft

Check the clutch release shaft a nd its pin for deflection or

damage.

If abnormal ity is found, replace it.

INSTALLATION

1. Drive in a new No.1 bush using special tools 09930-

30104 (A) and 09923-46 030 (B).

2. Appl y grease inside the bush.

(C): Lithium grease

3. Install the release shaft with the retur n spr ing fitted.

4. Apply grease inside No.2 bush (1) and press-fit it by

using the special tool 09922-46 010 (C ).

5. Appl y grease to the shaft seal (2) lip.

6. Use special tool 09925-98221 (D) to install the seal,

ensuring the face (lip) is downward (to ward the inside).

(E): Lithium grease

7. Stake the seal at A by using a staking tool and

hammer.

8. Hook the return s pring.

9. Apply grease inside the release bearing (1) and the

release shaft arm (2), then set the bearing.

(A): Lithium grease

10. Apply a small amount of grease to the input shaft (3)

spline and front end.

(B): Lithium grease

11. Set th e release leve r to the release s haft , alignin g their

punch marks (1).

12. Tighten the nut to the specified torque.

13. Install the clip (2) onto the clutch release shaft.

5. REQUIRED SERVICE MATERIAL

RELEASE LEVER BOLT TORQUE

SPECIFICATION (a) 23 Nm

Material Recommended product Use

Lithium grease Lithium grease •Cable end hook and joint pin.

•Release shaft bushes and s eal.

•Re lease shaft arm.

•Release bearing inside.

Lithium grease Input shaft spl ine and front end.

Sea lant Three Bond No. 1215 Flywheel bolt thread.

6. SPECIAL TOOLS

NOTE: Refer to Section 0A GENERAL INFORMATION – 7. CONSOLIDATED TOOLS for a detailed list of

special tools and the local equivalent if one is available.

09921-26020 09922-46010 09923-36320 09923-46020

Bearing remov er Bush remover Clutch centre guide Joint pipe

09923-46030 09924-17811 09925-98210 09925-98221

Joint pip e Flywheel hold er Input shaft bearing insta ller Bear ing inst aller

09930-30104

Sl iding shaft