Clutch installation how to replace clutch

Fig. Fig. 1: Clutch release bearing - 1990 Colt hatchback and sedan w/ 1.6L engine, 1990 Colt Wagon w/1.8L engine, and 1990-93 Vista

Fig. Fig. 2: Clutch driven and drive discs - 1990-93 all models

Fig. Fig. 3: Clutch release bearing - 1990 Colt Wagon w/1.5L engine, 1991-92 Colt hatchback and sedan w/4-speed and 1993 Colt hatchback and sedan w/1.8L engine

1. Remove the transmission or transaxle as outlined.
2. Insert a pilot shaft or an old input shaft into the center of the clutch disc, pressure plate, and the pilot bearing in the crankshaft.
3. With the pilot tool supporting the clutch disc, loosen the pressure plate bolts gradually and in a crisscross pattern.
4. Remove the pressure plate and clutch disc.
5. Clean the transmission and clutch housing. Clean the flywheel surface with a non-oil based solvent. Wash your hands before installing or handling the clutch assembly parts. Hold the clutch disc by the center hub only.

1. To remove the throwout bearing assembly: Remove the return clip and take out the throwout bearing carrier and the bearing.
2. To replace the throwout arm use a / 16 in. punch, knock out the throwout shaft spring pin and remove the shaft, springs, and the center lever.
3. Do not immerse the throwout bearing in solvent; it is permanently lubricated. Blow and wipe it clean. Check the bearing for wear, deterioration, or burning. Replace the bearing if there is any question about its condition.
4. Check the shafts, lever, and springs for wear and defects. Replace them if necessary.
5. If you hadn't planned on replacing the clutch disc, examine it for the following before reusing it. Loose rivets. Burned facing. Oil or grease on the facing. Less than 0.3mm left between the rivet head and the top of the facing.
6. Check the pressure plate and replace it if any of the following conditions exist: Scored or excessively worn. Bent or distorted diaphragm spring. Loose rivets.
7. Insert the control lever into the clutch housing. Install the two return springs and the throwout shaft.
8. Lock the shift lever to the shaft with the spring pin.
9. Fill the shaft oil seal with multipurpose grease.
10. Install the throwout bearing carrier and the bearing. Install the return clip.
11. Grease the carrier groove and inner surface.
12. Lightly grease the clutch disc splines.

1. Support the clutch disc and pressure plate with the pilot tool.
2. Turn the pressure plate so that its balance mark aligns with the notch in the flywheel.
3. Install the pressure plate-to-flywheel bolts head-tight. Using a torque wrench and, working in a crisscross pattern, tighten the bolts to 11-15 ft. lbs.
4. Install the transmission or transaxle as outlined.
5. Adjust the clutch as described in the following information.

1. Remove the transmission.

1. Matchmark the clutch cover (pressure plate) and flywheel, indicating their relationship.

1. Loosen the clutch cover-to-flywheel retaining bolts one turn at a time in a crisscross pattern. The pressure on the clutch disc must be released GRADUALLY.

1. Remove the clutch cover-to-flywheel bolts. Remove the clutch cover and the clutch disc.

1. If the clutch throwout bearing is to be replaced, do so at this time as follows:

1. Remove the bearing retaining clip(s) and remove the bearing and hub.
2. Remove the release fork and the boot.
3. The bearing is press fit to the hub. Turn the bearing by hand while placing it under some pressure; check for freedom of motion and lack of grinding or resistance. The bearing is permanently lubricated and cannot be disassembled or greased.
4. Clean all parts; lightly grease the input shaft splines and all of the contact points.
5. Install the bearing/hub assembly, fork, boot, and retaining clip(s) in their original locations.

1. Inspect the flywheel surface for cracks, heat scoring (blue marks), and warpage. If oil is present on the flywheel surface, this indicates that either the engine rear oil seal or the transmission front oil seal is leaking. If necessary, replace the seal(s). If in doubt concerning the condition of the flywheel, consult an automotive machine shop.

1. Before installing any new parts, make sure that they are clean. During installation, do not get grease or oil on any of the components, as this will shorten clutch life considerably. Grease or fingerprints may be cleaned with an evaporative cleaner such as the type used on brake linings.

1. Position the clutch disc against the flywheel. The long side of the splined section faces the flywheel.
2. Install the clutch cover over the disc and install the bolts loosely. Align the matchmarks made. If a new or rebuilt clutch cover assembly is installed, use the matchmark on the old cover assembly as a reference.
   

1. Align the clutch disc with the flywheel using a clutch aligning tool. These handy tools are available in many auto parts stores at a reasonable price. Do NOT attempt to align the clutch disc by eye; use an alignment tool.

1. With the clutch aligning tool installed, tighten the clutch cover bolts gradually in a star pattern, as is done with lug nuts. Final tighten the bolts to 14 ft. lbs. (19 Nm).
2. Apply molybdenum disulfide grease or multi-purpose grease to the release fork contact points, the pivot and the clutch disc splines. Install the boot, fork, and bearing on the transmission input shaft.
3. Install the transmission.

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Disconnect the negative battery cable.
   
3. Remove the transaxle.
   
4. Gradually loosen the clutch pressure plate bolts, in a crisscross pattern. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc.
   
5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
   
6. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
   
7. Install a flywheel holder to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
   
8. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
   
9. Inspect the release fork for wear or damage and replace as necessary.
   

Exploded view of the clutch assembly
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1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
   
2. Install the clutch release bearing on the release fork.
   
3. Install a new pilot bearing in the flywheel, if removed.
   
4. Be sure the flywheel mounting surface and the crankshaft or eccentric shaft mounting surfaces are clean. Remove any old sealant from the flywheel bolt hole threads and the flywheel bolts.
   
5. Install the flywheel.
   
6. Apply sealant to the flywheel bolt threads and install them hand-tight. Install the flywheel holding tool. Tighten the bolts, in a crisscross pattern, to 71–76 ft. lbs. (96–103 Nm).
   
7. Apply a small amount of molybdenum grease to the clutch disc splines and install the clutch disc on the flywheel, spring side toward the transaxle. Install a suitable alignment tool in the pilot bearing to position the clutch disc.
   
8. Install the clutch pressure plate, aligning the dowel holes with the flywheel dowels.
   
9. Install the pressure plate bolts and gradually tighten, in a crisscross pattern to 20 ft. lbs. (26 Nm). Remove the alignment tool.
   
10. Install the transaxle.