PL CLUTCH 6-1

CLUTCH
CONTENTS

page page

GENERAL INFORMATION CLUTCH DIAGNOSIS — RIGHT HAND DRIVE

CLUTCH COMPONENTS — RIGHT HAND (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DRIVE (RHD) . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
CLUTCH DISC AND COVER APPLICATION — CLUTCH ASSEMBLY — RIGHT HAND DRIVE
RIGHT HAND DRIVE (RHD) . . . . . . . . . . . . . 1 (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH REPLACEMENT — RIGHT HAND CLUTCH MASTER CYLINDER — RIGHT HAND
DRIVE (RHD) . . . . . . . . . . . . . . . . . . . . . . . . 1 DRIVE (RHD) . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION CLUTCH PEDAL POSITION SWITCH — RIGHT
CLUTCH PEDAL POSITION SWITCH — RIGHT HAND DRIVE (RHD) . . . . . . . . . . . . . . . . . . . 8
HAND DRIVE (RHD) . . . . . . . . . . . . . . . . . . . 2 HYDRAULIC SLAVE CYLINDER — RIGHT
HYDRAULIC CLUTCH SYSTEM — RIGHT HAND DRIVE (RHD) . . . . . . . . . . . . . . . . . . . 7
HAND DRIVE (RHD) . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS
DIAGNOSIS AND TESTING NV T350 (A-578) CLUTCH TIGHTENING
CLASH–INTO–REVERSE COMPLAINTS . . . . . . 6 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GENERAL INFORMATION nylon bushings and a shaft (Fig. 1). These bushings
are greased at assembly and do not require periodic
CLUTCH COMPONENTS — RIGHT HAND DRIVE lubrication.
(RHD)
The modular clutch assembly used in this vehicle
consists of a single, dry-type clutch disc and a dia-
phragm style clutch cover.
The clutch disc has cushion springs riveted to the
disc hub assembly. The clutch disc facings are riveted
to the cushion springs. The facings are made from a
non-asbestos material.
The clutch cover pressure plate assembly is a dia-
phragm type unit with a one-piece diaphragm spring
with multiple release fingers. The pressure plate
release fingers are preset during manufacture and
are not adjustable.
A sleeve-type release bearing is used to engage and
disengage the clutch cover pressure plate. The bear-
ing is prelubed during manufacture and is a sealed
unit. Fig. 1 Clutch Pedal Components
The release bearing is operated by a pivoting
CLUTCH DISC AND COVER APPLICATION —
release fork in the clutch housing. The fork pivots on
a ball stud within the housing. The release fork is RIGHT HAND DRIVE (RHD)
actuated by a hydraulic clutch system. The1.8L and 2.0L single overhead cam engines use
The hydraulic clutch automatically adjusts for any a 216 mm (8.5 in.) clutch disc.
slack in the mechanism. This compensates for clutch
disc wear. The system requires no maintenance or CLUTCH REPLACEMENT — RIGHT HAND DRIVE
lubrication. (RHD)
The clutch pedal is connected to the clutch master The transaxle must be removed to service the mod-
cylinder through a plastic bushing. The upper end of ular clutch assembly, drive plate, and/or clutch
the clutch pedal pivots in the pedal bracket on two release bearing and lever.
6-2 CLUTCH PL

DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING

HYDRAULIC CLUTCH SYSTEM — RIGHT HAND CLUTCH DIAGNOSIS — RIGHT HAND DRIVE
DRIVE (RHD) (RHD)
The hydraulic clutch linkage consists of a clutch Problem diagnosis will generally require a road
master cylinder, remote hydraulic fluid reservoir, test to determine the type of fault. Component
lower clutch slave cylinder, damper, and hydraulic inspection will then determine the problem after road
lines. The clutch master cylinder is connected to the testing.
clutch pedal. The slave cylinder push rod is con- Drive the vehicle at normal speeds during road
nected to the clutch release fork. The clutch master test. Shift the transaxle through all gear ranges and
cylinder is mounted on the driver’s side of the dash observe clutch action. If chatter, grab, slip, or
panel adjacent to the brake master cylinder and improper release is experienced, remove and inspect
booster assembly. the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
NOTE: The clutch hydraulic system is serviced as transaxle or other driveline components may actually
two separate systems (master cylinder assembly be at fault.
w/lines and lower slave cylinder assembly w/lines. If
a malfunction occurs within a system, replacement
of that system is required. It is not recommended or
necessary to bleed the clutch hydraulic system. The
service parts are prefilled.

CLUTCH PEDAL POSITION SWITCH — RIGHT

HAND DRIVE (RHD)
For description, operation, and diagnosis of the
clutch pedal position switch refer to the Left Hand
Drive (LHD) information for the clutch pedal position
switch.

Fig. 2 Clutch Pedal Position Switch and

Components — Right Hand Drive (RHD)
PL CLUTCH 6-3
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSIS—CLUTCH GRAB/CHATTER

CONDITION POSSIBLE CAUSES CORRECTION

CLUTCH DISC FACING Oil leak at engine rear main or Correct leak and replace w/modular
COVERED WITH OIL OR transaxle input shaft seal clutch assembly
GREASE Too much grease applied to splines Apply lighter coating of grease to
of disc and input shaft splines
NO FAULT FOUND WITH Problem actually related to Further diagnosis required. Check
CLUTCH suspension or driveline component engine/transmission mounts,
COMPONENTS suspension attaching parts and other
driveline components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT OF Clutch cover, spring, or release Replace w/modular clutch assembly
CLUTCH DISC fingers bent, distorted (rough
handling, improper assembly)
Clutch disc damaged or distorted Replace w/modular clutch assembly
Clutch misalignment Check alignment and runout of
flywheel, disc, or cover. Check clutch
housing to engine dowels and dowel
holes for damage. Correct as
necessary.
6-4 CLUTCH PL
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSIS—CLUTCH SLIPS

CONDITION POSSIBLE CAUSES CORRECTION

DISC FACING WORN OUT Normal wear. Replace w/modular clutch assembly.
Driver frequently rides (slips) clutch, Replace w/modular clutch assembly
results in rapid wear and
overheating.
Insufficient clutch cover diaphragm Replace w/modular clutch assembly
spring tension
CLUTCH DISC FACING Leak at rear main oil seal or Replace leaking seals. Replace
CONTAMINATED WITH OIL OR transaxle input shaft seal w/modular clutch assembly.
GREASE Excessive amount of grease applied Apply less grease to input shaft.
to input shaft splines Replace w/modular clutch assembly
Road splash, water entering housing Seal housing. Inspect clutch
assembly.
CLUTCH IS RUNNING Release bearing sticking or binding, Verify that bearing is actually
PARTIALLY DISENGAGED does not return to normal running binding. Then, replace bearing and
position. transmission front bearing retainer if
sleeve surface is damaged.
Hydraulic clutch mechanism sticking Verify that clutch slave cylinder and
or binding causing high preload fork are free to move
CLUTCH DISC FACINGS HAVE Driver performs a 5-1 downshift at Alert driver to problem cause.
FRACTURED INTO SMALL vehicle speed in excess of 60 miles Replace w/modular clutch assembly.
PIECES per hour
Leak at rear main or transaxle input Replace w/modular clutch assembly.
shaft seal Replace seal.
Excessive heat from slippage Replace w/modular clutch assembly
PL CLUTCH 6-5
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE

CONDITION POSSIBLE CAUSES CORRECTION

CLUTCH DISC BINDS ON INPUT Clutch disc hub splines damaged Clean, smooth, and lubricate disc
SHAFT SPLINES during installation and shaft splines. Replace
w/modular clutch assembly and/or
input shaft if splines are severely
damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on Clean input shaft splines and disc
splines of input shaft and disc splines, then lube
CLUTCH DISC RUSTED TO Occurs in vehicles stored or not Replace w/modular clutch assembly
FLYWHEEL AND/OR PRESSURE driven for extended period of time.
PLATE Also occurs after steam cleaning if
vehicle is not used for extended
period.
CLUTCH WILL NOT DISENGAGE Disc bent, distorted during transaxle Replace w/modular clutch assembly
PROPERLY installation
Clutch cover diaphragm spring Replace w/modular clutch assembly
damaged during transaxle
installation
Release fork bent, loose, or Replace fork if worn or damaged
damaged
Clutch pedal binding or does not Lubricate pedal bushings. Check
return system for leaks and replace as
needed
Hydraulic clutch system has air in Stroke pedal rapidly 20 to 30 times
the lines. to force air bubbles into reservoir.
Check for leaks. Replace appropriate
upper or lower hydraulic system.
6-6 CLUTCH PL
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSIS–CLUTCH PEDAL NOISE

CONDITION POSSIBLE CAUSES CORRECTION

CLUTCH PEDAL SQUEAKS Pedal bushings worn out or Replace or lubricate bushings
WHEN DEPRESSED TO FLOOR inadequate lubrication

CLASH–INTO–REVERSE COMPLAINTS
Some Right Hand Drive NV T350 (A-578) manual
transaxles are equipped with a reverse brake. It pre-
vents clash when shifting into reverse, but only if the
vehicle is not moving. See Group 21, Transaxle for
further diagnosis.
(1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time, and the reverse brake
may not be functioning.

NOTE: Verify that nothing is obstructing pedal

travel. Floormats or other articles located under-
neath the clutch pedal could prevent the clutch
from disengaging fully. Also make sure that the
hydraulic clutch release mechanism is functioning
properly. Fig. 3 Quick-Connect Coupler
(2) Remove transaxle. See Group 21, Manual Tran- (3) Lower vehicle.
saxle for procedure. (4) Unsnap hydraulic line from left rail retainer
(3) Check the input shaft spline, clutch disc clips (Fig. 4).
splines, and release bearing for dry rust. If present,
clean rust off and apply a light coat of bearing grease
to the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. Verify
that the clutch disc slides freely along the input shaft
spline.
(4) Check to see if the clutch disc hub splines are
damaged, and replace with new clutch assembly if
required.
(5) Check the input shaft for damaged splines.
Replace as necessary.
(6) Check for broken clutch cover diaphragm
spring fingers.
(7) Install clutch assembly and transaxle.

REMOVAL AND INSTALLATION

Fig. 4 Routing Clips
CLUTCH MASTER CYLINDER — RIGHT HAND (5) From underneath dash panel, remove cotter
DRIVE (RHD) pin from pedal bushing.
The clutch master cylinder and remote reservoir (6) Remove pedal pivot pin from master pushrod
are serviced as an assembly. The linkage components assembly and bushing.
and cylinder cannot be overhauled or serviced sepa-
rately. NOTE: Verify that the reservoir cap is on securely.
This is necessary to avoid undue spillage during
REMOVAL removal.
(1) Hoist vehicle.
(2) Disconnect quick-connector coupler at lower (7) Slide remote reservoir up out of bracket.
hydraulic damper using Special Tool 6638 (Fig. 3).
PL CLUTCH 6-7
REMOVAL AND INSTALLATION (Continued)
(8) Grasp clutch master cylinder and turn 1/4 turn (6) From underneath dash panel, ensure clutch
counterclockwise (Fig. 5). master cylinder push rod is located between the
pedal and locator bracket. Snap clutch pedal pin into
pushrod and slide cotter pin into bushing.
(7) Route hydraulic lines to retaining clips at
frame rail.
(8) Raise vehicle.
(9) Connect upper clutch hydraulic line from mas-
ter cylinder (quick–connect) to lower clutch hydraulic
line near damper.
(10) Check the operation of the hydraulic clutch
release system.
(11) Actuate clutch pedal rapidly 20–30 times.
Check for leaks

HYDRAULIC SLAVE CYLINDER — RIGHT HAND

DRIVE (RHD)
REMOVAL
Fig. 5 Hydraulic Clutch Master Cylinder
(1) Raise vehicle on hoist.
(9) Remove cylinder from dash panel. (2) Separate hydraulic line at quick-disconnect
using Special Tool 6638. (Fig. 7).
INSTALLATION (3) Remove nuts retaining hydraulic damper to
transaxle (Fig. 8).
NOTE: Verify that the reservoir cap is on securely.
(4) Remove engine mount bracket.
This is necessary to avoid undue spillage during
(5) Disconnect ground wire from starter.
installation.
(6) Remove two bolts retaining hydraulic slave cyl-
(1) Position clutch master cylinder to dash panel inder to transaxle (Fig. 8).
approximately 45° counterclockwise. (Fig. 6). (7) Remove slave cylinder from transmission.

Fig. 6 Master Cylinder at Dash Panel Fig. 7 Hydraulic Line

(2) Position master cylinder push rod so that INSTALLATION

retention fingers are facing towards the right side of
CAUTION: When reinstalling starter wiring, make
the vehicle.
certain wiring does not contact hydraulic tubing.
(3) Insert push rod through dash panel hole and
slide push rod eye between the clutch pedal and loca- (1) To install, reverse above procedure.
tor bracket. (2) Actuate clutch pedal 20–30 times. Check for
(4) Rotate cylinder 1/4 turn clockwise. leaks.
(5) Slide remote reservoir into bracket at dash
panel until locked in.
6-8 CLUTCH PL
REMOVAL AND INSTALLATION (Continued)
switch wires to seat switch into bracket, switch dam-
age may occur.
(3) Attach switch wiring harness to vehicle wiring
harness.
(4) After installation, the switch must be checked
for proper operation. Refer to Diagnosis and Testing
section for proper testing procedures.

CLUTCH ASSEMBLY — RIGHT HAND DRIVE (RHD)

The transaxle must be removed to service the mod-
ular clutch disc assembly and lever.

REMOVAL
(1) Remove the starter wiring. Remove the starter
assembly.
(2) Remove the rear transaxle support bracket.
Fig. 8 Damper and Slave Cylinder (3) Remove the front transaxle support bracket.
(4) Remove modular clutch retaining bolts.
CLUTCH PEDAL POSITION SWITCH — RIGHT (5) Remove transaxle. See Group 21, Manual Tran-
HAND DRIVE (RHD) saxle, for procedure.
The clutch pedal position switch is mounted to a (6) The transaxle and modular clutch come out as
bracket located behind the clutch pedal. The switch an assembly.
is held in place by four plastic wing tabs. (7) Remove the modular clutch assembly from the
The clutch pedal position switch IS NOT adjust- transaxle input shaft (Fig. 10). Handle carefully to
able. The pedal blade contacts the switch in the down avoid contaminating the friction surfaces.
position (Fig. 9).

Fig. 10 Clutch Components

Fig. 9 Clutch Pedal Position Switch and
INSPECTION
Components
(1) Inspect for oil leakage through engine rear
REMOVAL main bearing oil seal and transaxle input shaft seal.
(1) Disconnect electrical harness to switch connec- If leakage is noted, it should be corrected at this
tor. time.
(2) Depress wing tabs on switch and push switch
out of mounting bracket. Then slide wires through INSTALLATION
slot in bracket. (1) Mount modular clutch assembly onto input
shaft.
INSTALLATION (2) Install transaxle. See Group 21, Manual Tran-
(1) Slide switch wires through slot in switch saxle, for procedure.
bracket.
(2) Line up switch tab with slot in switch bracket NOTE: Use new bolts when mounting modular
and push switch into position. Do not pull on the clutch assembly to drive plate.
PL CLUTCH 6-9
REMOVAL AND INSTALLATION (Continued)
(3) To avoid distortion of the drive plate, bolts SPECIFICATIONS
should be tightened a few turns at a time. Use a
crisscross pattern, until all bolts are seated. Tighten NV T350 (A-578) CLUTCH TIGHTENING
bolts to 75 N·m (55 ft. lbs.) following a crisscross pat- REFERENCE
tern sequence.
(4) Install clutch inspection cover. DESCRIPTION TORQUE
(5) Install transaxle lower support brackets. Drive Plate To Clutch Bolts . . . . 75 N·m (55 ft. lbs.)
(6) Install starter assembly. Drive Plate To Crankshaft Bolts . 95 N·m (70 ft. lbs.)