TRANSMISSION & DRIVELINE

SECTION CL CLUTCH
B

CL

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 2 Hydraulic Layout ......................................................16 F
Removal and Installation .........................................16
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 2 UNIT REMOVAL AND INSTALLATION ...... 17 G
NVH Troubleshooting Chart ...................................... 2
CSC (CONCENTRIC SLAVE CYLINDER) ....... 17
PRECAUTION ............................................... 4 Exploded View .........................................................17
Removal and Installation .........................................17 H
PRECAUTIONS ................................................... 4
Precaution for Procedure without Cowl Top Cover...... 4 CLUTCH DISC AND CLUTCH COVER ............ 19
Service Notice or Precautions for Clutch .................. 4 I
MR20DD .....................................................................19
Precautions for Removing Battery Terminal ............. 4
MR20DD : Exploded View .......................................19
PREPARATION ............................................ 6 MR20DD : Removal and Installation .......................19
MR20DD : Inspection ..............................................20 J
PREPARATION ................................................... 6
HRA2DDT ..................................................................21
Special Service Tools ................................................ 6
HRA2DDT : Exploded View .....................................22
Commercial Service Tools ........................................ 6 K
HRA2DDT : Removal and Installation .....................22
PERIODIC MAINTENANCE .......................... 7 HRA2DDT : Inspection ............................................23

CLUTCH PEDAL ................................................. 7 K9K ............................................................................23 L

Inspection and Adjustment ........................................ 7 K9K : Exploded View ...............................................24
K9K : Removal and Installation ...............................24
CLUTCH FLUID ................................................... 8 K9K : Inspection ......................................................25
M
Inspection .................................................................. 8
R9M ............................................................................25
Air Bleeding Procedure ............................................. 8
R9M : Exploded View ..............................................26
REMOVAL AND INSTALLATION ............... 10 R9M : Removal and Installation ...............................26 N
R9M : Inspection ......................................................30
CLUTCH PEDAL ................................................10
Exploded View ........................................................ 10 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ......................................... 10 (SDS) ............................................................ 31 O
Inspection ................................................................ 11
SERVICE DATA AND SPECIFICATIONS
CLUTCH MASTER CYLINDER ..........................12 (SDS) ................................................................. 31 P
Exploded View ........................................................ 12 Clutch Control System .............................................31
Removal and Installation ......................................... 12 Clutch Pedal ............................................................31
Clutch Disc ..............................................................31
CLUTCH PIPING ................................................15 Clutch Cover ............................................................31
Exploded View ........................................................ 15

CL-1 GETtheMANUALS.org
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000010288552

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.

CL-2 GETtheMANUALS.org
 cause)

Symptom
Reference

ble)

disengage
Clutch slips
SUSPECTED PARTS (Possible

Clutch pedal spongy

Clutch grabs/judders
Clutch chatters/rattles

Clutch drags/does not

< SYMPTOM DIAGNOSIS >

Clutch noisy (whine/rum-

CLUTCH PEDAL (Inspection and adjustment) CL-7

1
1
CLUTCH LINE (Air in line) CL-8

2
1
EM-52 (HRA2DDT), EM-429 (R9M),
ENGINE MOUNTING (Loose)

1
EM-318 (K9K), EM-172(MR 2WD),EM-172 (MR 4WD)
CSC (Concentric Slave Cylinder) (Bearing Worn)

1
CL-17
CSC (Concentric Slave Cylinder) (fluid leak)

3
MASTER CYLINDER, DAMPER, OR PIPE (Fluid leak) CL-12

CL-3
CLUTCH DISC (Runout is excessive)

3
2
CLUTCH DISC (Lining broken)

3
2

2
CLUTCH DISC (Lining dirty or burned, Lining Oily, Lining worn out)

2
CLUTCH DISC (Cushion segment waving flattened)

2
CLUTCH DISC (Lack of spline grease)

3
CLUTCH DISC (Hub spline worn) (R9M)CL-30,(K9K),CL-25(HRA2DDT) CL-23CL-20

2
CLUTCH DISC (Damper worn or contaminated with oil/grease)

1
2
DIAPHRAGM SPRING (Damaged or weakened)

4
3
DIAPHRAGM SPRING (Out of tip alignment)

4
2
PRESSURE PLATE (Distortion)

5
3

4
PRESSURE PLATE DRIVE STRAPS (Distorted or broken)

4
3
EM-102 (HRA2DDT), EM-459 (R9M),
FLYWHEEL (Distortion)

5
3

5
EM-348 (K9K), (MR20DDT) EM-179
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DUAL MASS FLYWHEEL (Damper damaged or worn) EM-459 (R9M),EM-102 (HRA2DDT), EM-348 (K9K), (MR20DDT)EM-179

2
4
TRANSAXLE (Worn) TM-91(RS6F95R),TM-38 (RS6F94R),TM-150 (RS6F52A)

GETtheMANUALS.org
I

L
F

P
K
E
B
A

N
CL

H
C

O
G

M
 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000010497459

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

Service Notice or Precautions for Clutch INFOID:0000000010288554

CAUTION:
• Recommended clutch fluid is brake fluid “DOT 4”. Refer to MA-59, "Fluids and Lubricants".
• Never reuse drained clutch fluid.
• Never splash clutch fluid on painted areas.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-
tem.
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.
• Never disassemble master cylinder and CSC.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
Precautions for Removing Battery Terminal INFOID:0000000010508556

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.

CL-4 GETtheMANUALS.org
 PRECAUTIONS
< PRECAUTION >
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door. A
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
B
D4D engine : 20 minutes
K9K engine : 4 minutes
M9R engine : 4 minutes C
R9M engine : 4 minutes
V9X engine : 4 minutes
CAUTION: CL
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal. E
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF) F
1. Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied. G
2. Open the driver side door.
3. Open the hood.
4. Close the driver side door. H
5. Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of I
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal.
CAUTION: J
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

CL-5 GETtheMANUALS.org
 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000010288555

Tool number
Description
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover

ZZA0508D

— Holding the clutch cover.

Emb.1761 Assembly of three bolts, three spacers, and
Kit for clutch cover removal and instal- three nuts.
lation

E1BIA0775ZZ

— Rearming the clutch cover compensation sys-

Emb.1604 tem.
Clutch compression tool

E1BIA0778ZZ

— Locking the flywheel.

Mot.1431
Flywheel locking tool

JMAIA0431ZZ

Commercial Service Tools INFOID:0000000010288556

Tool name Description

Clutch aligner Installing clutch disc
1: Center shaft
2: Attachment
3: Guide

PCIB0017E

SAC tool (Self Adjusting Clutch) Installing clutch cover on R9M engine

CL-6 GETtheMANUALS.org
 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000010288557
B

INSPECTION
1. Check to see if the master cylinder rod end moves freely. It C
should not be bound by the clutch pedal.
• If the rod end does not move freely, remove the rod end and
check for deformation or damage on the rod end. Leave the
CL
rod end removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the E
clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the clutch pedal assembly.
Reverify that the master cylinder rod end moves freely.
PCIB1491E F
3. Inspect the ASCD clutch switch position and Interlock clutch
switch position
a. If the rod end does not move freely, check that the ASCD clutch switch and Interlock clucth switch are not
applying pressure to the clutch pedal causing the rod end to bind. To adjust, disconnect the ASCD clutch G
switch electrical connector and turn the ASCD clutch switch.
b. Connect the ASCD clutch switch and Interlock clutch switch electrical connector.
H
4. Check the clutch hydraulic system components (master cylinder assembly, CSC) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair is necessary, bleed the clutch hydraulic system. Refer to CL-8, "Air Bleeding
I
Procedure".
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system. J
ADJUSTMENT
Adjust ASCD clutch switch (1) position and Interlock clutch switch
(2) position so that clearance between clutch pedal and thread end K
of ASCD clutch switch and Interlock clutch switch, with clutch pedal
fully released, is within specification “A” or "B".
L
Clearance “A” : Refer to CL-31, "Clutch Pedal".
Clearance “B” : Refer to CL-31, "Clutch Pedal".
M

E1DIA0228ZZ
N

CL-7 GETtheMANUALS.org
 CLUTCH FLUID
< PERIODIC MAINTENANCE >
CLUTCH FLUID
Inspection INFOID:0000000010288558

CLUTCH FLUID LEVEL

• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any clutch fluid leakage around the reservoir
tank.
• Check the clutch system for any leakage if the fluid level is
extremely low (lower than MIN).

JPFIA0007ZZ

Air Bleeding Procedure INFOID:0000000010288559

NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Bleed the air of bleeding connector (1).
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
3. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.

PCIB1494E

4. Push the lock pin (1) of the bleeding connector (2), and maintain
the position.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con-
nector when fluid pressure is applied in the tube.

JPDIB0041ZZ

CL-8 GETtheMANUALS.org
 CLUTCH FLUID
< PERIODIC MAINTENANCE >
5. Slide clutch tube (1) in the direction of the arrow as shown in the
figure. A
•
2 : Clutch housing

B
Dimension “A” : 10 mm (0.39 in)
6. Depress the clutch pedal soon and hold it, and then bleed the air
from the piping. C
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con- JPDIB0042ZZ
nector when fluid pressure is applied in the tube. CL
7. Return clutch tube and lock pin to their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid. E

CL-9 GETtheMANUALS.org
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CLUTCH PEDAL
Exploded View INFOID:0000000010288560

E1DIA0227GB

1. Clutch pedal 2. Interlock clutch switch 3. Clip

4. Spring 5. Cluctch switch (ASCD Cancel 5. Nuts
Switch)
6. Stroke sensor
Refer to GI-4, "Components" for the symbols in the figure.

Removal and Installation INFOID:0000000010288561

REMOVAL
1. Remove front kicking plate inner and dash side finisher. Refer to INT-18, "Removal and Installation".
2. Remove lower instrument panel, driver side. Refer to IP-13, "Removal and Installation".
3. Disconnect ASCD clutch switch and Interlock clutch switch harness connector and then disconnect clip of
harness from clutch pedal assembly.
4. Disconnect clutch stroke sensor harness connector.
5. Remove clutch stroke sensor. Refer to CL-10, "Removal and Installation".

CL-10 GETtheMANUALS.org
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
6. Remove master cylinder rod end from clutch pedal assembly.
7. Remove clutch pedal assembly. A

PCIB1491E

CL
INSTALLATION
Install in the reverse order of removal.
CLUTCH STROKE SENSOR INSTALLATION E
1. Inserted the part (1) of the clutch stroke (2) into the hole and
slide it as shown on the figure.
F

H
E1DIA0240ZZ

2. Push the part (2) in the direction (B) to the hole deeply. I
Turn the part (1) in counterclockwise until the part in completely
fixed.
Push the part (5) on the direction (C) to cover the cluch pedal
rod (4). J

E1DIA0241ZZ L
Inspection INFOID:0000000010288562

INSPECTION AFTER REMOVAL M

Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace
clutch pedal assembly.
N

CL-11 GETtheMANUALS.org
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
Exploded View INFOID:0000000010288563

JPDIB0035ZZ

1. Reservoir tank assembly 2. Hose 3. Master cylinder assembly

Removal and Installation INFOID:0000000010288564

REMOVAL
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never disassemble master cylinder.
1. Remove the air cleaner case and air duct (inlet) or air ducts. Refer to EM-23, "Removal and Installation"
(HRA2DDT), EM-380, "Removal and Installation" (R9M), EM-279, "Removal and Installation" (K9K),
(MR20DD) EM-147, "Removal and Installation". (For LHD)
2. Remove cowl top assembly. Refer to EXT-29, "Removal and Installation" .
3. Remove engine room insulator. (for RHD).
4. Drain clutch fluid in reservoir tank assembly and then remove hose.

5. Remove master cylinder rod end from clutch pedal assembly.

PCIB1491E

CL-12 GETtheMANUALS.org
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
6. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). A
7. Rotate master cylinder assembly clockwise by 45° and then
remove master cylinder assembly from the vehicle.
B

PCIB1497E

CL
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. E
1. Tilt master cylinder assembly clockwise by 45° and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple is upward of the vehicle. F
2. Install master cylinder rod end to clutch pedal assembly.
3. Install hose to reservoir tank assembly and master cylinder
assembly. G
CAUTION:
Set hose with painted mark facing upward.
H
SCIA1286E

4. Install clutch tube (1) into connector of master cylinder assembly I

(2) until it stops.
5. Install lock pin (3) into connector of master cylinder assembly
until it stops. J
6. Fill new clutch fluid according to the following.
a. Fill reservoir tank assembly with new clutch fluid.
b. Connect a transparent vinyl hose to air bleeder of bleeding con- K
nector.

PCIB1500E
L

c. Push the lock pin (1) of the bleeding connector (2).

• RS6F94R, RS6F95R and RS6F52A M

JPDIB0041ZZ
P

d. Slide clutch tube (1) in the direction of the arrow as shown in the figure.

CL-13 GETtheMANUALS.org
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
• RS6F94R, RS6F95R and RS6F52A

2 : Clutch housing

Dimension “A” : 10 mm (0.39 in)

e. Depress clutch pedal slowly to full stroke and then release it.
Repeat this until new clutch fluid comes out.
CAUTION:
• Hold it to prevent releasing clutch tube from bleeding
connector when fluid pressure is applied in the tube. JPDIB0042ZZ
• Monitor clutch fluid level in reservoir tank to make sure it
does not empty.
f. Place clutch tube (1) and lock pin back into position with clutch pedal depressed.
g. Bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure".
7. After completing this procedure, inspect for clutch pedal. Refer to CL-7, "Inspection and Adjustment".
8. Install engine room insulator. (For RHD)
9. Install cowl top assembly. Refer to EXT-29, "Removal and Installation". (For RHD with R9M)
10. Install the air cleaner case and air duct (inlet) or air ducts. Refer to EM-380, "Removal and Installation"
(R9M), EM-23, "Removal and Installation" (HRA2DDT), EM-279, "Removal and Installation" (K9K), EM-
147, "Removal and Installation" (MR20DD). (For LHD)

CL-14 GETtheMANUALS.org
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
A
Exploded View INFOID:0000000010288565

RS6F94R RS6F95R B

CL

G
JPDIB0050ZZ

1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket

H
4. Clutch damper 5. Master cylinder assembly

RS6F52A
I

JPDIB0054GB
N
1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket
4. Clutch damper 5. Master cylinder assembly
O
Refer to GI-4, "Components" for the symbols in the figure.

CL-15 GETtheMANUALS.org
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
Hydraulic Layout INFOID:0000000010288566

PCIB1499E

1. Clutch tube 2. Lock pin 3. CSC (Concentric Slave Cylinder)

4. Clutch damper 5. Master cylinder assembly 6. Clutch pedal assembly

Removal and Installation INFOID:0000000010288567

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
Refer to the figure for removal procedure.
INSTALLATION
Refer to the figure for installation procedure.
• When installing clutch tube to connector of CSC, connector of clutch damper and connector of master cylin-
der, push it as far as it goes.
• When installing lock pin to connector of CSC, connector of clutch damper and connector of master cylinder,
push it as far as it goes.
• After installation, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure".
CAUTION:
Never scratch or damage clutch hose.

CL-16 GETtheMANUALS.org
 CSC (CONCENTRIC SLAVE CYLINDER)
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View INFOID:0000000010288568
B

MR20DD, HRA2DDT and K9K

C

CL

JPDIB0040GB
H
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)
Refer to GI-4, "Components" for symbols not described on the above.
I
R9M

JPDIB0048GB

1. Transaxle assembly 2. CSC (Concentric Slave Cylinder) 3. Sealing bolt O

Refer to GI-4, "Components" for symbols not described on the above.

Removal and Installation INFOID:0000000010288569 P

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
CL-17 GETtheMANUALS.org
 CSC (CONCENTRIC SLAVE CYLINDER)
< UNIT REMOVAL AND INSTALLATION >
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-148, "Removal and Installation" (4WD) or TM-
88, "Removal and Installation" (2WD) .
2. Remove mounting bolts and then remove CSC from clutch housing.
INSTALLATION
1. Install CSC to clutch housing and then tighten bolts to the specified torque.
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2. Install transaxle assembly. Refer to TM-148, "Removal and Installation" (4WD) or TM-88, "Removal and
Installation" (2WD) .
3. Bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure".

CL-18 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
A
MR20DD
MR20DD : Exploded View INFOID:0000000010654843
B

CL

JPDIB0049GB

H
Flywheel Clutch disc Clutch cover
Input shaft
First step Final step I

: N·m (kg-m, ft-lb)

: Apply lithium-based grease including molybdenum disulphide. J
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

MR20DD : Removal and Installation INFOID:0000000010654844 K

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position L
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to CL-17, "Removal and Installation".
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent. M
REMOVAL
1. Remove transaxle assembly. Refer to TM-35, "Removal and Installation". N
2. Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Never drop clutch disc.
O
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
P
4. Perform inspection after removal. Refer to CL-20, "MR20DD : Inspection".
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

CL-19 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
2. Apply recommended grease to clutch disc and input shaft
splines area . For recommended grease, refer to CL-19,
"MR20DD : Exploded View".
CAUTION:
Be sure to apply grease to the points specified. Otherwise,
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.
JSDIA3617ZZ

3. Install clutch disc using clutch aligner (A) (commercial service

tool), and temporarily install clutch cover.
CAUTION:
• Never drop clutch disc and clutch cover.

JSDIA3358ZZ

• Be careful with the orientation of the clutch disc.

: Engine side

JSDIA6017ZZ

4. Tighten clutch cover mounting bolts to the specified torque

evenly in two steps in the numerical order as shown in the fig-
ure.
• For tightening torque, refer to CL-19, "MR20DD : Exploded
View".
• After installation, perform inspection. Refer to CL-20,
"MR20DD : Inspection".
5. Install transaxle assembly. Refer to TM-35, "Removal and Instal-
lation".

PCIB1772E

MR20DD : Inspection INFOID:0000000010654845

INSPECTION AFTER REMOVAL

Clutch Disc

CL-20 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. A

Runout limit/diameter of the area to : Refer to CL-31,

be measured "Clutch Disc" . B
• Measure backlash to clutch disc spline and input shaft spline at the
circumference of clutch disc. If it is outside the specification,
replace clutch disc. C

Maximum allowable spline backlash : Refer to CL-31,

SCL221
(at outer edge of disc) "Clutch Disc".
CL
• Measure the depth (A) to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
E
Facing wear limit (depth to the rivet : Refer to CL-31,
head) "Clutch Disc".
F

G
JPDIB0026ZZ

Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover. H
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down. I
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
INSPECTION AFTER INSTALLATION J
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height, K
using the diaphragm adjusting wrench (A) (SST: ST20050240).

Tolerance for diaphragm spring : Refer to CL-31, L

lever unevenness "Clutch Cover".

JPDIB0160ZZ
N
HRA2DDT

CL-21 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
HRA2DDT : Exploded View INFOID:0000000010288570

E1DIA0242GB

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
A. First step B. Final step
: Apply lithium-based grease including molybdenum disulphide.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
Refer to GI-4, "Components" for symbols not described on the above.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

HRA2DDT : Removal and Installation INFOID:0000000010288571

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-35, "Removal and Installation" (RS6F94R).
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.

CL-22 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
3. Install clutch disc using a suitable clutch aligner (A).
4. Install clutch cover. Pre-tighten clutch cover mounting bolts. A
5. Tighten clutch cover mounting bolts evenly to the specified
torque in two steps in the order shown in the figure.
6. Install transaxle assembly to the vehicle. Refer to TM-35, B
"Removal and Installation" (RS6F94R).

E1DIA0243ZZ

CL
HRA2DDT : Inspection INFOID:0000000010288572

INSPECTION AFTER REMOVAL E

CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. F

Runout limit/diameter of the : Refer to CL-31,

area to be measured "Clutch Disc".
G
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc. H

Maximum allowable spline : Refer to CL-31,

SCL221
backlash (at outer edge of disc) "Clutch Disc".
I
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
J
Facing wear limit (depth to the : Refer to CL-31,
rivet head) "Clutch Disc".
K

L
JPDIB0026ZZ

CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever M
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].
N
Tolerance for diaphragm : Refer to CL-31,
spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or O
breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
P
rivet with a hammer. PCIB0276E

• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
K9K

CL-23 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
K9K : Exploded View INFOID:0000000010288573

JPDIB0039GB

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
: Apply lithium-based grease including molybdenum disulphide.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
Refer to GI-4, "Components" for symbols not described on the above.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

K9K : Removal and Installation INFOID:0000000010288574

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-35, "Removal and Installation".
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.

CL-24 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
3. Install clutch disc using a suitable clutch aligner (A).
4. Install clutch cover. Pre-tighten clutch cover mounting bolts. A
5. Tighten clutch cover mounting bolts evenly to the specified
torque in the order shown in the figure.
6. Install transaxle assembly to the vehicle. Refer to TM-35, B
"Removal and Installation".

E1DIA0243ZZ

CL
K9K : Inspection INFOID:0000000010288575

INSPECTION AFTER REMOVAL E

CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. F

Runout limit/diameter of the : Refer to CL-31,

area to be measured "Clutch Disc".
G
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc. H

Maximum allowable spline : Refer to CL-31,

SCL221
backlash (at outer edge of disc) "Clutch Disc".
I
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
J
Facing wear limit (depth to the : Refer to CL-31,
rivet head) "Clutch Disc".
K

L
JPDIB0026ZZ

CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever M
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].
N
Tolerance for diaphragm : Refer to CL-31,
spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or O
breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
P
rivet with a hammer. PCIB0276E

• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
R9M

CL-25 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
R9M : Exploded View INFOID:0000000010288579

E1DIA0229GB

1. Manual Transmission 2. Concentric slave cylinder (CSC) 3. Bolt

4. Clutch assembly bolt 5. Spacer 6. Clutch cover
7. Clutch disc 8. Flywheel
Refer to GI-4, "Components" for symbols not described on the above.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

R9M : Removal and Installation INFOID:0000000010288580

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-148, "Removal and Installation" or TM-88,
"Removal and Installation".

CL-26 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
2. Lock the flywheel using the tool [SST: — (Mot.1431)] (1).
A

E1BIA0774ZZ

CL
3. Remove three clutch cover mounting bolts at 120° intervals.
4. Replace these three bolts by the tool [SST: — (Emb.1761) (1)].
CAUTION: E
Never drop clutch disc.
5. Place the three spacers of tool [SST: — (Emb. 1761)] in contact
using the nuts. F
6. Gradually remove the six remaining bolts.

E1BIA0776ZZ
H
7. NOTE:
These instructions must be respected to prevent twisting the clutch cover:
• Unscrew and gradually remove by quarter turns the three nuts of tool [SST: — (Emb. 1761)] one by one. I
8. Remove clutch cover.
9. Remove clutch disc.
J

INSTALLATION
K
1. In case of clutch cover re-used follow the procedure below :
NOTE:
The automatic compensation must be repositioned at its first point.
L
a. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
b. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage M
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts. N
c. Place the base of tool (1) [SST: — (Emb.1604)] in a vice jaw.

E1BIA0779ZZ

CL-27 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
d. Install clutch cover onto the base plate then the ball bearing or
bronze ring (1) and the nut (2).

E1BIA0780ZZ

e. Tighten the nut (1) fully.

E1BIA0781ZZ

f. Fit a circlip clamp at (1).

E1BIA0783ZZ

g. Compress the spring (1) to reprime the automatic compensa-

tion.
h. Slacken off the nut (2) completely (spring compressed).
i. Release the clutch cover.

E1BIA0783ZZ

j. Remove the clutch cover from the base plate of tool [SST: —
(Emb.1604)].
NOTE:
Be sure that the springs are correctly compressed.

E1BIA0784ZZ

CL-28 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
k. Install clutch disc on flywheel using a suitable clutch aligner (A).
A

E1DIA0235ZZ
CL
l. Install clutch cover (2) on flywheel (1). Fit the Self Adjusting
tools (A) using 3 of the cover bolt fixing holes.
E

G
E1DIA0236ZZ

m. Use Self Adjusting Clutch tools (A) to depress diaphram fingers H

until cover body fixing flange touches flywheel.

E1DIA0237ZZ K

n. Fit cover bolts in the 6 available holes and tighten to the speci-
fied torque. Refer to CL-26, "R9M : Exploded View" .
L

E1DIA0238ZZ

o. Remove Self Adjusting Clutch tools. O

Fit bolts in the 3 remaining holes and tighten to the specified
torque. Refer to CL-26, "R9M : Exploded View" .
Remove the disc alignement tool (A). P

E1DIA0239ZZ

CL-29 GETtheMANUALS.org
 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
p. Install transaxle assembly to the vehicle. Refer to TM-88, "Removal and Installation" (2WD) or TM-148,
"Removal and Installation" (4WD).

R9M : Inspection INFOID:0000000010288581

INSPECTION AFTER REMOVAL

CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the : Refer to CL-31,

area to be measured "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.

Maximum allowable spline : Refer to CL-31,

SCL221
backlash (at outer edge of disc) "Clutch Disc".
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

Facing wear limit (depth to the : Refer to CL-31,

rivet head) "Clutch Disc".

JPDIB0026ZZ

CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].

Tolerance for diaphragm : Refer to CL-31,

spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
rivet with a hammer. PCIB0276E

• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.

CL-30 GETtheMANUALS.org
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000010288582
B

Type of clutch control Hydraulic

C
Clutch Pedal INFOID:0000000010288583

Unit: mm (in) CL
Clearance “A” between clutch pedal and ASCD switch threaded
0.2 - 1.96 (0.008 - 0.0772)
end while clutch pedal is fully released.
Clearance “B” between clutch pedal and Interlock switch threaded
0.2 - 1.96 (0.008 - 0.0772)
E
end while clutch pedal is fully released.

Clutch Disc INFOID:0000000010288584

F
Unit: mm (in)

Engine type HRA2DDT K9K R9M MR20DD

Model 225 240 230
G

Facing size (Outer dia. × Inner 225 × 150 × 2.9 (8.9 × 225 × 150 × 2.9 (8.9 × 239 × 170 × 3.45 (9.41 230 × 155 × 3.2
dia. × Thickness) 5.91 × 0.114) 5.91 × 0.114) × 6.69 × 0.1358) (9.06 × 6.10 × 0.126)
H
1.0 (0.039) /230 (9.06)
Runout limit/diameter of the 1.0 (0.039) /215 (8.46) 1.0 (0.039) /215 (8.46) 1.0 (0.039) /240 (9.45)
dia.
area to be measured dia. dia. dia.

Maximum allowable spline I

1.2 (0.047) 1.28 (0.0504) 0.9 (0.035)
backlash (at outer edge of disc)
Facing wear limit (depth to the
replace if worn to rivet head 0.3 (0.012)
rivet head) J

Clutch Cover INFOID:0000000010288585

K
Engine type HRA2DDT K9K MR20DD R9M
Transaxle type RS6F94R RS6F52A (4WD) RS6F95R (2WD)
L
5,730 N (584.5 kg, 7,100 N (724.2 kg, 5,700 N (581.4 kg,
Set-load 8,800 N (897.6 kg, 1978.2 lb)
1,288.1 lb) 1416.2 lb) 1,281.4 lb)
Tolerance for diaphragm
spring lever unevenness
1.2 mm (0.047 in) or less not specified 0.8 mm (0.031 in) or less M

Diaphragm spring lever 12.6 - 16.2 mm 12.8 - 14.8 mm 20.7 - 22.7 (0.815 -
26.6 - 29.0 mm (1.047 - 1.142 in)
height (new clutch) (0.496 - 0.64 in) (0.504 - 0.583 in) 0.8937)
N

CL-31 GETtheMANUALS.org