Transmission Clutch

Clutch
Specifications
Torque
Description Value
Nut - Master Cylinder to Dash Panel 19–25 Nm
Nut - Master Cylinder and Hard Tube 15–18 Nm
Nut - Slave Cylinder Hose and Slave Cylinder 15–18 Nm
Nut - Slave Cylinder to Manual Transmission Slave Cylinder 19–25 Nm
Bracket
Air-bleeder Plug - Clutch Slave Cylinder 9–15 Nm

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Clutch Transmission
Parameter
Type Single Plate Dry Type, Hydraulic Booster Type Clutch

Driven Disc Diameter 215 mm

Pressure Plate Diameter 216 mm
Rivet Depth:
New 1.0 m above Rivet Head
Service Limit 0.2 m above Rivet Head

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Transmission Clutch

Description and Operation

System Component Layout
Clutch System

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1. Clutch Pedal 8. Clutch Slave Cylinder Exhaust Valve

2. Master Cylinder 9. Clutch Pedal Stroke Adjusting Nut
3. Brake Reservoir Hose 10. Clutch Pedal Switch
4. Clip - Brake Reservoir Hose 11. Manual Transmission Input Shaft
5. Clutch Hard Tube 12. Release Bearing
6. Slave Cylinder Hose 13. Clutch Cover Assembly
7. Slave Cylinder 14. Driven Disc

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15. Flywheel 16. Bolt (6)

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Description sheets, which will pull the pressure plate off the driven disc
General Description when the clutch pedal is pressed. The clutch housing is made of
stamped steel plates. The diaphragm spring is a cast ring, in the
This is a conventional three-piece diaphragm type clutch with
inner circle of which there are 18 release fingers. Two circular
a hydraulic clutch release system which consists of two main
support rings are fitted on the housing, so that the diaphragm
parts, a master cylinder and a slave cylinder.
spring can turn between them. The diaphragm spring is not
Clutch Hydraulic System connected to the pressure plate directly. When the release
The master cylinder of the clutch is directly fitted on the dash bearing applies pressure to the release fingers of the diaphragm
panel of the passenger compartment, and the push rod of the spring, the diaphragm spring will turn around the support rings
master cylinder piston is secured to the clutch pedal with a pin. and leave the pressure plate. At the same time, the springs of
the pressure plate connected to the housing leave the driven
The clutch hard line is connected to the master cylinder with
disc too.
a rotary union, and the other end of the line is connected to
the slave cylinder hose with a rotary union as well. Driven Disc

The clutch slave cylinder, which is fitted on the bracket of

the manual transmission case, and the release rocker arm,
release fork and release bearing form a release mechanism,
while the release bearing is supported and secured by a guide

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sleeve fitted on the transmission input shaft. The release fork
positions the release bearing against the diaphragm spring of
the clutch when releasing.
Clutch Mechanical System
The model with a manual transmission is equipped with a single
mass flywheel. The clutch cover assembly is fitted on the
flywheel with location pins and fixed by 6 bolts.
Clutch Cover Assembly 1. Driven Disc Body
2. Friction Lining
3. Spline Hub
4. Torsional Shock Absorber
The driven disc is fitted between the flywheel and the pressure
plate, its feature is the spline hub engages with the splines on
the input shaft of the transmission. The friction lining consists
of two plates, which are riveted on each side of the driven disc
body. The rivets are fitted in the holes of the friction lining and
holes on the other side to prevent from damaging the pressure
plate and the flywheel.
Clutch Switch

1. Diaphragm Spring
2. Clutch Cover
3. Pressure Plate
4. Support Ring
5. Leaf Spring
The clutch cover assembly consists of the diaphragm spring,
the pressure plate, and the cover. The pressure plate is made
of cast iron and has a machined smooth surface to combine
with the driven disc. There are three loops on the outer
circle of the pressure plate, then the loops are connected to
the housing by springs. The springs are three tempered steel

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The clutch switch is located on the bracket of the clutch pedal,
and it is powered by ECM.
When the clutch pedal is pressed, the push lever of the switch
is released from the pedal arm and ejected by the force of
the inner spring, resulting in disconnection of contact points in
the switch, at this time,ECM receives the clutch release signal;
when the clutch pedal returns, the pedal arm is against the push
lever of the switch, and overcomes the spring force to close
contact points in the switch,ECM receives the clutch engage
signal.

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Transmission Clutch

Operation Clutch Switch

Hydraulic Pressure Operation When the clutch pedal is pressed, the clutch switch is
When the clutch pedal is pressed, the piston is pushed into activated.ECM uses signals from the clutch switch for the
the master cylinder. The piston makes the fluid in the master following functions:
cylinder move along the clutch line. The pressure is applied to
• Reducing shocks during shifting
the slave cylinder piston, which will move under the hydraulic
pressure. When the clutch pedal is released, the force of Reducing shocks during shifting to prevent the engine
the diaphragm spring release finger pushes the release bearing. speed from increasing rapidly. Reducing shocks to
The release bearing pushes the piston back to the slave cylinder improve driving performance in the following.
by the release fork and release rocker arm, then presses the • Smoother shifting
fluid back to the clutch line and the master cylinder.
• Better exhaust emission control
Mechanical Operation
• Improved fuel consumption
When the clutch pedal is pressed, the fluid in the slave cylinder
The clutch switch receives a 12 V reference voltage from ECM.
pushes the piston to move. The movement of the piston
When the clutch pedal is in the reset position, the switch is
pushes the clutch release bearing towards the release finger of
grounded. When the clutch pedal is pressed,ECM receives a
the diaphragm spring by the release rocker arm and the release
12 V signal.
fork, the diaphragm spring will rotate around the support ring

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of the pressure plate housing. Along with the deformation When the clutch switch is malfunctioning, any of the following
of the diaphragm spring, its pressure on the pressure plate signs may be seen:
disappears. The three leaf springs will pull the pressure plate • Reducing shocks is unavailable
away from the driven disc.
The disappearance of the pressure that the pressure plate
applied to the driven disc reduces the friction between the
driven disc and flywheel. The driven disc will slip on the
flywheel, the power of the flywheel cannot be transferred to
the input shaft of the transmission.
When the clutch pedal is released, the pressure on the piston
of the slave cylinder disappears. After that, it makes the release
finger of the diaphragm spring push the release bearing to slide
along the guide sleeve, which pushes the release fork and the
release rocker arm to push the piston of the slave cylinder back
to the slave cylinder.
The diaphragm spring rotates around the support ring of
the pressure plate housing. Thus, pressure is applied to the
pressure plate, and the resistance of the spring is overcome.
This pressure makes the pressure plate move towards the
flywheel and apply pressure to the driven disc.
The pressure that the pressure plate applies to the driven disc
increases the friction between the driven disc and flywheel.
After the clutch pedal is released, the friction increases,
the rotation of flywheel is transferred to the driven disc,
which then transfers the rotation to the input shaft of the
transmission.
When the pedal is released completely, the force that the
diaphragm spring applies to the pressure plate will press the
driven disc on the flywheel, resulting in no sliding between
them.

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Service Procedures or irregular height.
Clutch Assembly 2. Check the driven disc of the clutch for wear or signs of
Removal oil contamination. If necessary, replace the driven disc.
1. Remove the manual transmission assembly. 3. Measure the thickness of the clutch disc, if it is less than
Manual Transmission Assembly Removal the service limit, replace the driven disc.
2. UseT10028 to hold the flywheel.

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Thickness of the Driven Disc (when it is being
3. Gradually loosen and remove the 6 bolts securing the compressed) A
clutch cover assembly to the flywheel.
New driven disc 7.2 mm
4. Remove the clutch housing assembly and take out the
Service limit 5.7 mm
driven disc.
4. Measure the depth of the rivet, if it is less than the
service limit, replace the driven disc.
Rivet Depth B

New driven disc 1.0 mm

Service limit 0.2 mm

5. Check the pressure plate for wear or signs of damage.

Check the drive plate for signs of overheating (dark
yellow to blue), if necessary, replace the pressure plate.
Caution: If the clutch pressure plate has been dropped
accidentally, it must be replaced. When replacing the
worn driven plate, it is advised that the pressure plate
5. Remove the release bearing.
should also be replaced.
6. With a straightedge and feeler gauge, check the surface
flatness of the pressure plate at 4 separate points. If
the deformation stroke is more than the service limit,
replace the pressure plate.

Inspection
1. Visually check the diaphragm release fingers for wear

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Deformation of Pressure Plate 8. UseT22001 to fit the clutch assembly to the flywheel.

Service limit 0.15 mm

7. Check the release bearing for wear or signs of damage,

if necessary, replace it.

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8. Clean the pressure plate and flywheel, location pin and
pin hole.
9. Check the flywheel for signs of scratch or other
damage. If there is any wear or damage, replace it.
Refit
1. Clean the guide sleeve of the release bearing.
2. Lubricate the guide sleeve of the release bearing with
molybdenum disulphide grease.
9. Fit the 6 bolts securing the pressure plate to the
3. Fit the release bearing.
flywheel, and tighten them by hand.
4. Apply molybdenum disulphide grease to the splines of
10. UseT10028 to hold the flywheel, and gradually tighten
the clutch driven disc.
the bolts to 25 Nm in diagonal order.
5. Be careful about the fitting direction when securing the
11. Remove the driven disc alignment tool T22001.
driven disc to the pressure plate.
12. Fit the manual transmission assembly.
6. UseT22001 to align the driven disc with pressure plate.
Manual Transmission Assembly Refit

7. Ensure the driven disc is aligned with the pressure plate

centre.

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Clutch Release Bearing Clutch Master Cylinder
Removal Removal
1. Remove the manual transmission assembly. 1. Drain the brake fluid from the brake reservoir.
Manual Transmission Assembly Removal Note: Brake fluid can damage painted surfaces. If brake
fluid is accidentally spilled on painted surface when
2. Remove the release bearing from the transmission
adding it, soak up any spillage with a piece of absorbent
input shaft guide sleeve.
cloth immediately and swab the area with water or car
cleaner.
2. Disconnect the brake reservoir hose and the reservoir
tank.

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Refit
1. Clean the mating surfaces between the release bearing
and the bearing guide sleeve. 3. Disconnect the master cylinder and the EVP pipe.
2. Lubricate the bearing moving surface with molybdenum 4. Remove the driver side sealed panel assembly.
disulphide grease.
5. Release the pin and the master cylinder push lever of
3. Set the release bearing on the transmission input shaft the clutch pedal.
guide sleeve, and fit the release bearing to the release
fork.
4. Fit the manual transmission assembly.
Manual Transmission Assembly Refit

6. Remove the 2 nuts securing the clutch master cylinder

to the dash panel and remove the master cylinder.
Refit
1. Position the master cylinder on the dash panel, fit the
nuts and tighten them to 19–25 Nm.
2. Apply grease to the inside of the clutch pedal pin hole,
hold the master cylinder push lever to the clutch pedal
and fix it with a pin.
3. Connect the master cylinder with the EVP pipe and
tighten to 15–18 Nm.
4. Fit the driver side sealed panel assembly.
5. Connect the brake reservoir hose with the reservoir

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tank. Clutch Slave Cylinder

6. Bleed the clutch line system. Removal

Clutch Line System Bleeding 1. Drain the brake fluid from the brake reservoir.

7. Add brake fluid into the reservoir tank to the MAX line. Note: Brake fluid can damage painted surfaces. If brake
fluid is accidentally spilled on painted surface when
adding it, soak up any spillage with a piece of absorbent
cloth immediately and swab the area with water or car
cleaner.
2. Disconnect the slave cylinder and the slave cylinder
hose.

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3. Loosen the 2 nuts securing the slave cylinder to the
slave cylinder bracket of the manual transmission.

4. Remove the slave cylinder.

Refit
1. Connect the slave cylinder and the slave cylinder hose
and tighten to 15–18 Nm.
2. Push the end of the slave cylinder push lever against the
base hole of the release rocker arm.
3. Secure the slave cylinder to the slave cylinder bracket
of the manual transmission and tighten the nut to
19–25 Nm.
4. Bleed the clutch line system.
Clutch Line System Bleeding
5. Add brake fluid into the reservoir tank to the MAX line.

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Clutch Line System Bleeding
Bleeding
Bleed the air entering the hydraulic system when disconnecting
the line to repair. When bleeding, the brake fluid in the brake
reservoir must be kept at the MIN line or above.
Warning: DO NOT allow the brake fluid to contact your
eyes or skin.
Caution: Never reuse the brake fluid that has been bled
from the clutch line system.
Caution: Ensure the level of new brake fluid in the brake
reservoir is between the MIN and MAX throughout the
whole bleed procedures.
1. Raise the vehicle on the lift.

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2. Remove the air-bleeder plug dust cover from the slave
cylinder of the clutch, and fit the hose to the air-bleeder
plug. Submerge the free end of the hose into a glass
container half full of new brake fluid.
3. Fully press the clutch pedal and hold it to ensure the
maximum system pressure.
4. Loosen the air-bleeder plug to bleed the air in the fluid,
the system pressure decreases at this time.
5. First tighten the air-bleeder plug to prevent back flow
of fluid and air.
6. Smoothly release the clutch pedal to the maximum
stroke, make it return without any external force to
supplement brake fluid sufficiently.
7. Operate several times in the above order until brake
fluid without any air flows into the container, then keep
the clutch pedal in the maximum stroke position, and
tighten the air-bleeder plug to 9–15 Nm.
8. Remove the hose from the air-bleeder plug, and fit the
air-bleeder plug dust cover.
9. Add brake fluid into the reservoir tank to the MAX line.

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Special Tools
Tool Description Picture
Number

Flywheel
T10028
Locking Tool

T22001 Clutch Aligner

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