1. Master Cylinder
2. Clutch Reservoir
3. Reservoir Hose
4. Spring Clamp
5. Release Cylinder Assembly
6. Release Cylinder
7. Release Cylinder Bracket
8. Release Hose
9. Hydraulic Clutch Pipe
10. Clamp
11. Release Lever
12. Bushing
13. Pin
14. main shaft Oil Seal
15. Bolt
16. Release Bearing
17. Bearing Guide Sleeve
18. O-Ring
19. Input Shaft Seal
20. Screw Plug
21. Magnet
22. Release pork
23. Back up lamp switch
24. washer

1. Clutch Pedal Brace
2. Nut
3. Washer Spring
4. Turn Over Spring
5. Spring Bushing
6. Bushing
7. Pedal Brace Bracket
8. Bolt
9. Clutch Pedal Shaft
10. Clutch Pedal
11. Pedal Plate Cover
12. Pin
13. Bushing
14. Bushing

1. Flywheel
2. Clutch Disc
3. Pressure Plate
4. Release Bearing

Checks	Action
DEFINITION: When the pedal is pressed to the floor, the shift lever does not move freely in and out of reverse gear.
Check for a loose linkage.	Repair or replace loose linkage, if necessary.
Check for a damaged clutch disc.	Replace the damaged clutch disc.
Check for an improperly installed fork shaft.	Remove and properly reinstall the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.
Check for the clutch disc hub binding on the input shaft splines.	Repair or replace the clutch disc hub.
Check for a warped or bent clutch disc.	Replace the warped or bent clutch disc.

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for an oil-soaked clutch disc.	Correct the leak at its source and install a new clutch disc.
Check for worn facing or facing torn from the disc.	Replace the worn disc with a new disc.
Check for warped pressure plate or a warped flywheel.	Replace the pressure plate.
Check for a driven plate that is not seated.	Start the engine 30 to 40 times. Do not overheat the engine.
Check for a driven plate that is overheated.	Allow the driven plate to cool.

Checks	Action
Check for burned or glazed facing caused by oil on the facing.	Correct the leak at its source and install a new clutch disc.
Check for worn splines on the input shaft.v	Replace the worn input shaft.
Check for a warped pressure plate or a warped fly wheel.	Replace the warped pressure plate or the warped flywheel.
Check for burned or smeared resin on the flywheel or the pressure plate.	Sand off the burned or smeared resin if it is superficial. Replace any or heat-checked parts.

Checks	Action
Check for weak retracting springs.	Replace the pressure plate.
Check for a loose release fork.	Remove and reinstall the release fork properly.
Check for oil in the driven plate damper.	Correct the cause of the oil leak and replace the driven disc.
Check for a damaged driven plate damper spring.	Replace the driven disc.

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for a binding release bearing.	Clean and re-lubricate the release bearing. Inspect the release bearing for burrs and nicks.
Check for an improperly installed release lever.	Remove and reinstall the release lever properly.
Check for a weak linkage return spring.	Replace the weak linkage return spring.

Checks	Action
Check for a worn release bearing.	Replace the worn release bearing.
Check for an improperly installed release lever.	Remove and properly reinstall the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.

Checks	Action
Check for binding in the linkage or the release bearing.	Lubricate and freeup the binding linkage or the release bearing.
Check for weak pressure plate springs.	Replace the pressure plate.

Checks	Action
Check for binding in the linkage.	Lubricate and free-up the binding linkage.
Check for a worn driven plate.	Replace the worn driven plate.

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1. Disconnect the negative battery cable.
2. Disconnect the return spring from the mount brace.



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3. Remove the nut, the washer, and the pedal mounting shaft.
Installation Notice

Tightening Torque

18N•m(13lb-ft)




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4. Remove the locking washer and the piston rod bolt.
5. Remove the clutch pedal with the return spring from the vehicle.

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1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the left front wheel. Refer to Section 2E, Tires and Wheels.
4. Remove the engine under covers. Refer to Section 9N, Frame and Underbody.
5. Remove the transaxle from the vehicle. Refer to Section 5B. "Five-Speed Manual Transaxle".
6. Remove the pressure plate bolts and the pressure plate. Support the pressure plate when you remove the last bolt.



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Adjustment Notice :
• Coat the spline on the clutch disc with multi-purpose grease.
• Align the pressure plate and the clutch disc onto the flywheel using the clutch arbor J-42474.
Installation Notice

Tightening Torque

15N•m (11lb-ft)




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7. Remove the clutch disc.



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8. Remove the release fork bolt.
Installation Notice

Tightening Torque

35N•m(26lb-ft)




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9. Pull the clutch release shaft upward, out of the transaxle.



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10. Remove the fork and the release bearing from the release bearing guide sleeve.
Installation Notice
• Coat the release bearing bore with multi-purpose grease.



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11. Remove the release lever shaft bushings.
Installation Notice
• Coat the bushing bores with multi-purpose grease.



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12. Remove the release bearing guide sleeve bolts and the release bearing guide sleeve.
Installation Notice

Tightening Torque

5N•m(45lb-in)

• Coat the sleeve surface with multi-purpose grease.



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13. Remove the input shaft seal from the release bearing guide sleeve.
Installation Notice
• Install the input shaft seal into the release bearing guide sleeve. Use input shaft seal installer J-36547 with a hammer.



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14. Remove the O-ring from the groove in the transaxle case.
15. Installation should follow the removal procedure in the reverse order.

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1. Determine the clutch pedal play. Depress the clutch pedal lightly with your hand and measure the distance when you feel resistance.



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2. Adjust the clutch pedal play. Loosen the lock nut and turn the pushlod. Clutch pedal play should measure 6 to12 mm (0.2 to 0.5 inch). Tighten the locknut after adjustment.



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3. Measure the clutch pedal travel. Press the clutch pedal all the way to the floor. Measure from the starting position to the ending position.



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4. Adjust the clutch pedal travel. Loosen the locknut and turn the bolt. Clutch pedal travel should measure more than 130 mm (5.1 inches). Tighten the locknut after adjustment.

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1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse position, depress the clutch pedal slowly and measure the distance between the point when gear noise is not heard and the point the clutch pedal is completely depressed. The distance should be more than 30 mm (1.2 inches).
4. If the distance is not more than 30 mm (1.2 inches), check the following:
• Clutch pedal height
• Clutch pedal play
• Air in the system
• Clutch cover and disk

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Notice : Bleed the hydraulic system to remove the air which entered when the pipes were disconnected for repairs. The clutch/brake fluid in the clutch/brake reservoir must be maintained at the MIN level or higher during air bleeding. Right-hand drive vehicles use a separate clutch fluid reservoir.
1. Attach a vinyl hose to the bleeder plug. Place the other end of the vinyl tube in a glass container half-filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleeder screw until the fluid starts to run out. Close the bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the fluid.
5. Fill the reservoir with clutch fluid up to the MAX level.

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Notice : Before disconnecting the reservoir tank hose, remove the clutch/brake fluid from the reservoir tank. Right-hand drive vehicles use a separate clutch fluid reservoir.
1. Disconnect the negative battery cable.
2. Disconnect the spring clamp on the master cylinder. Remove the reservoir hose.



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3. Disconnect the pipe connected to the master cylinder.



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4. Remove the locking washer and the piston rod bolt from the clutch pedal and piston rod clevis.
5. Installation should follow the removal procedure in the reverse order.



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6. Remove the lock nuts on the master cylinder bracket. Remove the master cylinder in the direction of the engine compartment.
Installation Notice

Tightening Torque

22N•m(16lb-ft)

• Bleed the air. Refer to "Air bleeding" in this section.
• Adjust the clutch pedal. Refer to "Clutch Pedal Adjustment" in this section.
7. Installation should follow the removal procedure in the reverse order.

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1. Disconnect the negative battery cable.
2. Remove the bolt and disconnect the hose from the clutch release cylinder.
Adjustment Notice:
• Bleed the air. Refer to "Air bleeding" in this section.
• Adjust the clutch pedal. Refer to Clutch Pedal Adjustment (Hydraulic)" in this section.
• Fill the reservoir with clutch/brake fluid up to the MAX level.



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3. Remove the clutch release cylinder bolts and remove the release cylinder from the transaxle.
Installation Notice

Tightening Torque

60N•m(44lb-ft)

4. Installation should follow the removal procedure in the reverse order.

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1. Drain the clutch oil
2. Disconnect the reservoir hose and remove the clutch reservoir
3. Installation should follow the removal procedure in the reverse order.

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1. Remove the clutch master cylinder assembly from the vehicle. Refer to "Clutch Master Cylinder Assembly" in this section.
2. Remove the boot and disconnect the piston stop ring using ring pliers.



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3. Remove the push rod assembly and the piston assembly.
4. Inspect the clutch master cylinder wall and the piston for wear. Replace the piston if necessary.
5. Inspect the cup and the piston for wear. Fluid leaks will show wear on the cup and the piston. Replace the cup and the piston if necessary.
6. Inspect the push rod for wear. Repair the pushrod if necessary.
Installation Notice
• Apply clean fluid to the piston assembly cup and insert the piston assembly and the pushrod assembly into the master cylinder body.
7. Assembly should follow the disassembly procedure in the reverse order.

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1. Remove the clutch release cylinder assembly from the vehicle. Refer to "Clutch Release Cylinder Assembly" in this section.
2. Remove the bolts and brackets.



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3. Remove the boot and the push rod.



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4. Compress the piston with a driver, and then remove the snap ring with snap ring pliers.
5. Remove the piston assembly.
6. Assembly should follow the disassemly procedure in the reverse order.
Installation Notice
• Apply clean clutch fluid to the piston and the cup.

Application	N•m	Lb-Ft	Lb-In
Clutch Fork to Release Lever Shaft Bolt	35	26	-
Clutch Master Cylinder Locknuts	22	16	-
Clutch Pedal Nut	18	13	-
Pressure Plate to Flywheel Bolts	15	11	-
Release Bearing Guide Sleeve Bolts	5	-	45
Release Cylinder Bolts	60	44	-

	J-36547 Input Shaft Seal Installer
	J-42474 Clutch Arbor