GENERAL INFORMATION REMOVAL AND INSTALLATION

1. SPECIFICATION.................................... 3 3010-00 TROUBLESHOOTING.................. 15

2. TIGHTENING TORQUE.......................... 4 3010-00 CIRCUIT DIAGRAM OF
INTERLOCK SWITCH................... 16
3020-00 AIR BLEEDING............................. 17
OVERVIEW AND OPERATING 3010-00 INSPECTION AND
PROCESS MAINTENANCE............................ 18
3010-01 CLUTCH DISC & COVER
1. OVERVIEW............................................ 5 ASSEMBLY.................................. 20
2. SATIC (SELF ADJUSTING 3191-11 CONCENTRIC SLAVE
TECHNOLOGY WITH INTEGRATED CYLINDER.................................... 25
CASSETTE)........................................... 6 3020-01 CLUTCH MASTER CYLINDER
3. DUAL MASS FLYWHEEL (DMF)............. 9 AND RELEASE CHAMBER........... 27
3030-01 CLUTCH PEDAL........................... 34
CONFIGURATION

3010-01 CLUTCH ASSEMBLY................... 10

3020-01 CLUTCH MASTER CYLINDER..... 11
3020-06 CLUTCH RELEASE CHAMBER.... 13
3030-01 CLUTCH PEDAL........................... 14
 0000-00 04-3

1. SPECIFICATION
Description Specification
Operating type Hydraulic type
Clutch cover Type Diaphragm spring strap
Adjusting type SATIC (Self Adjusting Technology with
Integrated Cassette) type
Clutch pedal Type Suspended type
Max. operating travel 135 ± 3 mm
Pedal free play (Longitudinal) 7.1 ± 3 mm
Pedal free play (Transverse) 3 mm
Clutch disc Type Dry type single diaphragm (Rigid type)
Diameter of facing Outer: 250 ± 1 mm
Inner:160 ± 0.8 mm
Thickness of disc Free: 8.7 ± 0.3 mm
When loaded: 8.0 ± 0.2 (at 7,800 N)
Numbers of disc 2
Weight 1.18 kg
Flywheel type DMF (Dual Mass Flywheel)
Setting load of clutch cover assembly At least 7,800 N
Clutch master Operating travel 30 mm
cylinder
Inner diameter 17.46 mm
Concentric slave Maximum operating travel 12.55 mm
cylinder
Operating pressure Maximum 50 bar
Clutch oil Standard DOT 3 or DOT 4
Capacity As required
04-4

2. TIGHTENING TORQUE
Tightening torque
Description Amount

Upper (17 mm) 85.0 to 100 Nm 2

Front (14 mm) 54.0 Nm + 20° 1
Clutch housing bolt
Rear (14 mm) 51.3 to 56.7 Nm 2
Lower (14 mm) 56.0 to 62.0 Nm 4
Pressure plate assembly bolt (Hexagon 6 mm) 21.0 to 27.0 Nm 6
Concentric slave cylinder bolt (Hexagon 5 mm) 10 to 16 Nm 3
Concentric slave cylinder oil pipe nut 24.5 to 28.4 Nm Remove the nut if it is
necessary. (Once
removed, apply the
Loctite on the thread
before installation.)
Master cylinder nut (12 mm) 7.8 to 17.6 Nm
Master cylinder oil pipe nut (10 mm) 14.7 to 17.6 Nm
Master cylinder push rod lock nut 8.8 to 13.7 Nm
Clutch oil chamber screw and bolt (10 mm) 3.9 to 7.8 Nm
Oil pipe nut (10 mm) 14.7 to 17.6 Nm
Clutch pedal mounting nut (12 mm) 7.8 to 17.6 Nm
Stopper bolt 16 to 22 Nm
 0000-00 04-5

1. OVERVIEW
The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric
slave cylinder fitted to the clutch housing as a hydraulic pressure.
(The hydraulic pressure is transmitted in the following order: Clutch pedal - Clutch master
cylinder - Clutch pipe - Clutch damper - Clutch pipe and hose - Concentric slave cylinder -
Pressure plate - Flywheel.)
If a driver depress the clutch pedal, the hydraulic pressure is generated in the master cylinder. It
is transmitted to the concentric slave cylinder through the pipe, resulting in the cylinder being
forced out. At this time, the clutch disc is forced against the cylinder by pushing the cover. This,
in turn, remove the flywheel from the pressure plate. As a consequence, the power from the
engine will be cut off and the gear change can be carried out.
04-6

2. SATIC (SELF ADJUSTING TECHNOLOGY WITH

INTEGRATED CASSETTE)
1) System Description
▶ Function

On the conventional clutch, the pedal force

tends to increase in proportion to the degree
of disc run-out. However, the SATIC clutch
has the adjusting function which activates the
cassette system inserted to the clutch cover
to maintain a constant pedal force and
clearance when the disc runs out. (Unlike SAT
type, SATIC type does not need SST for
clutch cover removal.)

▶ Operation

Diaphragm spring rotates the adjusting

equipment as clutch disc is wearing and so,
pressure plate is pushed to clutch disc side at
the amount of wear.
Disc wear (Free play) → Diaphragm spring (1)
→ Adjusting equipment (2, 3) → Pressure
plate (4)
 0000-00 04-7

2) Overview
▶ Driving elements
The driving elements consist of two flat surfaces machined to a smooth finish.
One of these is the rear face of the engine flywheel and the other is the clutch pressure plate. The
clutch pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel.

▶ Driven elements
The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the
splines of the input shaft.
The driving and driven elements are held in contact by spring pressure. This pressure is exerted
by a diaphragm spring in the clutch cover pressure plate assembly.

▶ Operating Elements
The clutch "release" system consists of the clutch pedal and clutch release cylinder.
This system directly releases the clutch by using hydraulic pressure while the conventional clutch
system releases the clutch by using release lever and release fork. This system provides higher
efficiency than conventional clutch system, and its durability is superior.
- Clutch master cylinder (mounted on clutch pedal)
- Concentric slave cylinder pipe (mounted inside of transmission)
04-8

3) Layout

Clutch disc Clutch cover assembly

Clutch setting jig

Dual mass flywheel (DMF) Concentric slave cylinder

 0000-00 04-9

3. DUAL MASS FLYWHEEL (DMF)

The dual mass flywheel (DMF) is of having a mass divided into two halves.
While one mass is connected to the engine crankshaft, which is affected by the mass moment of
inertia of the engine, the other mass is affected by one of the transmission.
The divided dual masses are connected to the coil spring and damping system internally.

▶ The DMF has the following benefits:

- Reducing fuel consumption by lowering engine speed
- Reducing rattling noise and vehicle vibration in all driving ranges
- Reducing synchronization wear
- Facilitating gear change
- Protecting power train parts by preventing excessive load from being delivered

1. Primary flywheel
2. Secondary flywheel
3. Arc damper spring
4. Torque limiter
5. Ring gear
04-10

Clutch assembly is composed of clutch cover (diaphragm spring, pressure plate) and clutch disc.

▶ Clutch disc

The clutch disc is installed between the

engine flywheel and the pressure plate. The
spline part is installed in the center of the disc
and transmits the engine's electric power to
the transmission. The transmission input shaft
can be inserted into the spline part. The
clutch disc has friction materials on its edges,
where the engine power can be interrupted,
and the cushion spring is installed to prevent
friction materials (facing) from unevenly
wearing out.
▶ Clutch cover
When depressing the clutch pedal, the concentric slave cylinder pushes the pressure plate
diaphragm and separates the pressure plate. The advantages of using the diaphragm spring: the
pressure varies only a little even when the clutch disc facing is considerably worn out, its structure
is simple, and the pedal effort is small.

Pressure plate cover

Pressure
plate

Diaphragm spring
 3020-01 04-11

The clutch master cylinder generates the

hydraulic pressure by moving the piston
within the cylinder. It consists of oil tank,
cylinder, piston, piston cup spring and push
rod, and the clutch fluid is supplied from the
brake fluid reservoir tank.

▶ Operation
When depressing the clutch pedal, the push rod pushes the piston and the piston cup, which
sends the oil in the oil reservoir tank to the concentric slave cylinder through the hose and pipe.
During this operation, an oil pressure is produced within the master cylinder and transmitted as
follows: concentric slave cylinder → clutch cover → clutch disc.
When releasing the clutch pedal, it returns to its original position through the motion of the clutch
cover and the spring within the cylinder, and the clutch operation stops. The piston in cylinder
returns to its original position.

Installation

Brake & clutch fluid reservoir

Nipple

Clutch reservoir
hose

The clutch master cylinder is located on the

Clamp
dash board in engine compartment, and the
clutch fluid is supplied from brake oil reservoir.
Brake master Clutch master
Clutch fluid: DOT 3 or DOT 4
cylinder cylinder
Change interval: every 2 years
04-12

▶ Component

1. Master cylinder body

2. Piston assembly
3. Push rod
4. Retainer ring
5. Coil spring
6. O-ring
7. Screw
8. Hose
9. Clamp
 3020-06 04-13

▶ Operation

The clutch release chamber keeps the oil

pressure in the clutch hose and pipe stable
and also helps the oil pressure to transfer
quickly and generates the remaining pressure
in the hose and pipe when the clutch is
operated.

▶ Installation

Pipe to master cylinder

Pipe to concentric
slave cylinder
Master cylinder

Release chamber

Concentric slave cylinder

04-14

▶ Operation

1. Pendant type clutch pedal (leverage

effect is applied to reduce the effort to
the feet).
2. The clutch pedal has some free play that
prohibits its operation prior to generating
Clutch interlock the resistance by depressing the pedal
switch (operate) and touching the release bearing pressure
plate. This free play is to prevent the
clutch disc from burning out that is
resulted from the overheating caused by
the clutch slipping while driving. If this
free play is too wide, engine power
disconnection is difficult and the gear
damage with abnormal noise will occur.
Clutch interlock The clutch pedal has a clutch interlock
switch (release) 3. switch that prevents an abrupt start or
unexpected incidents due to the faulty
transmission when starting the engine.

Installation

Signal
Switch

Ground
3010-00 04-15
04-16
 3020-00 04-17

Front view

Bleed bolt

Clutch hose

▶ Procedure
1. Remove the air bleed bolt cap on the
release cylinder.
2. Connect a plastic tube to the bolt. Put the
other side of the tube into a empty
container.
3. Slowly pump the clutch pedal several
times.
Brake & clutch fluid reservoir
4. With clutch pedal fully depressed, undo
the air bleed bolt and bleed the air and
fluid from the fluid line.
5. Repeat step 3 through 4 until no more air
- This work has to be done by two service bubbles are in the escaping fluid.
persons.
- After bleeding, check the clutch system
for operation and noise. - Keep the fluid level over MAX in reservoir
- Use only the Ssangyong genuine clutch during bleeding operation.
fluid, and check the clutch fluid level in - Do not let the fluid contact a painted
reservoir. surface.
04-18

▶ Clutch cover assembly

- Check the diaphragm spring tip for wear

and height unevenness.

Wear limit 0.6 mm

- Check the pressure plate surface for

wear, crack and discoloration.
- Check the strap plate rivet for looseness
and replace the clutch cover if necessary.

▶ Pressure plate

- Check the pressure spring for wear.

The excessively worn components should

be replaced.

▶ Clutch disc

- Check the facing for rivet looseness, sticks,

oil and grease.
- Measure the rivet head depth. If it is out of
limit, replace the disc.

Wear limit 0.3 mm

▶ Clutch disc run-out

- Measure the clutch disc run-out and if it is

out of limit, replace the disc.

Limit below 0.7 mm

 3010-00 04-19

▶ Concentric slave cylinder

- Check any heat damage, abnormal noise,

poor rotation and wear of the concentric
slave cylinder bearing.
04-20

&
▶ Component

1. Disc & cover set - Clutch

3. Bolt
4. Washer
 3010-01 04-21

- Disconnect the negative cable from the battery.

- Remove the engine and transmission assembly from the vehicle.

1. Install an engine jack on the transmission mounting hook and unscrew the mounting bolts in the
following order.

a. Unscrew the transmission mounting b. Unscrew the 4 transmission lower

bolt (14 mm) on the left side. When mounting bolts (14 mm).
installing the bolt, tighten the bolt (A)
and then a further 15 to 20 degrees.

c. Unscrew the two transmission d. Unscrew the two transmission right

upper mounting bolts (17 mm). mounting bolts (17 mm).
04-22

2. Remove the transmission assembly from the engine assembly.

3. Loosen the clutch cover bolts 1/2 turns in

cross sequence until the spring tension is
released.

DMF
Clutch cover 1. Do not remove the bolts at a time, or
clutch cover may be damaged or
Crankshaft
deformed.
Clutch disc

Setting
slave
 3010-01 04-23

4. Unscrew the bolts completely and remove the clutch cover assembly and clutch disc.

Be careful not to drop the clutch disc.

Clutch cover assembly Clutch disc

Make sure that the clutch disc is fitted the

right way round. (Name label should point
toward the transmission.)

Cautions when replacing SATIC clutch for engine D20DTF

- The clutch must be replaced as a set.

- If you need to re-install the clutch due to replacing of the DMF or other parts, it is not
necessary to use the dismantling jig. However, do not remove and install the clutch several
times.
Repeating the removal and installation of the clutch several times will cause deterioration and
early run-out of the clutch disc, resulting from repeated activation of the self adjusting
function.
04-24

5. Install the clutch disc and cover in the

reverse order of removal.
Use the clutch setting jig when installing
them.
 3191-11 04-25

▶ Component

1. Unscrew the 3 concentric slave cylinder

hex. mounting bolts (5 mm) on the clutch
housing.

2. Remove the concentric slave cylinder from

the transmission input shaft. At this time,
disconnect also the oil pipe connected to
the cylinder.
04-26

3. Install in the reverse order of removal.

- Before installation, clean all the

components.
- Do not re-use the used clutch fluid.
- Apply a small amount of clutch fluid on
the internal components such as piston.
- Replace parts if necessary.
- After the removal and installation are
completed, air bleeding must be
performed.
- Follow the specified torque for installing
the concentric slave cylinder.
 3020-01 04-27

RELEASE CHAMBER
▶ Component

1. Clutch master cylinder assembly

2. Nut
5. Oil pipe to master cylinder
6. Release chamber
7. Bolt
8. Oil pipe to transaxle
9. Adapter assembly
11.Hose clip
12.Bracket
04-28

1) Clutch Master Cylinder

1. Drain the brake fluid (clutch fluid).

Do not re-use the drained brake fluid

(clutch fluid).

2. Remove the fuel filter assembly.

3. Disconnect the clutch fluid supply hose

from the brake fluid reservoir.

4. Disconnect the clutch fluid supply pipe

(chamber side) from the master cylinder.
 3020-01 04-29

5. Unscrew the two clutch master cylinder

mounting nuts (12 mm).

6. Remove the push rod for the clutch master

cylinder from the clutch pedal. (For details,
refer to section "Clutch Pedal".) Remove
the clutch master cylinder from the
dashboard.

7. Install the clutch master cylinder in reverse

order of removal. After the installation is
completed, bleed the cylinder and check
the functionality of the pedal.
04-30

2) Clutch Release Chamber & Pipe

1. Drain the brake fluid (clutch fluid).

2. Remove the fuel filter assembly.

1. Disconnect the clutch fluid supply pipe (10

mm) from the clutch master cylinder.

2. Disconnect the primary supply pipe (A) and the secondary supply pipe (B) from the clutch
release chamber. Unscrew the two chamber mounting bolts (10 mm) to remove the release
chamber (C) and the supply pipes.

Clutch release chamber Tightening torque

1. For clutch release chamber (C) mounting
bolt: 3.9 to 7.8 Nm
2. For pipe (A and B) mounting nut:
14.7 to 17.6 Nm

Disengage mounting clip

for primary supply pipe
 3020-01 04-31

3. Install in the reverse order of removal.

1. Make sure to bleed the air from the system after installation.
2. Check each pipe bolt for oil leaks.
3. Clutch pipes are reusable. However, you must check the pipes for damages and cracks.

Chamber & pipes

To master cylinder
Secondary pipe

Primary pipe

Clutch release
chamber

To concentric slave
cylinder hose
04-32

3) Disassembly and Assembly of Clutch Master Cylinder

Clutch fluid hose

Nipple
Bolt

O-ring

Master cylinder body

Retainer ring

Spring Piston Push rod

1. Disengage the clamp on the clutch master

cylinder to disconnect the clutch fluid supply
hose.
 3020-01 04-33

2. Unscrew the mounting screw and remove

the nipple from the master cylinder.

3. Remove the retainer ring in the master

cylinder using e.g. a screwdriver.

4. Remove the push rod, piston and spring

from the master cylinder in turn.

5. Assemble in the reverse order of

disassembly. Clean the disassembled parts
with the brake fluid and apply the
dedicated grease onto the piston during
assembling.
04-34

▶ Component

1. Clutch pedal assembly

6. Clutch pad
10.Clutch interlock switch
11.Stopper pad
18.Clevis pin
20.Nut
 3030-01 04-35

1. Remove the IP side panel (A).

2. Unscrew the two side mounting screws

on the IP lower panel (B).

3. Pull the lower panel to disconnect the

following parts then remove the IP lower
panel assembly.

a. Disconnect the switch connector (A) for

the lower panel.
04-36

b. Disconnect the diagnostic connector

(B) on the lower part of the lower
panel.

c. Disconnect the engine hood cable (C).

4. Remove the clutch interlock switch (D) and

ABS/ESP clutch interlock switch (E) from
the clutch pedal.

5. Unscrew the lock nut on the interlock

switch to remove the two interlock
switches.
 3030-01 04-37

6. Remove the snap pin (B) from master

cylinder push rod (A).

Securely install the snap pin as shown in

figure.

7. Unscrew the two clutch master cylinder

mounting nuts (12 mm).

8. Unscrew the two mounting nuts (12 mm)

on the clutch pedal assembly indoors and
remove the clutch pedal assembly.
04-38

▶ Installation notice

Install in the reverse order of removal.

Adjust pedal stroke after installation.

1. Apply long-life grease (T/M DBL

6611.00) to the connections.
2. Remove foreign materials.
3. Keep the tightening torque.
4. Replace the bushings with new ones.
5. Fit the connector securely until a click is
heard.

▶ Inspection & adjustment

1. Pedal stroke (A)

- Unscrew the lock nut (C) for the stopper

bolt (B), turn the stopper bolt until the
correct height (travel) is obtained and then
tighten the lock nut.

Max. operating travel 12.55 mm

2. Pedal free play

- Unscrew the master cylinder lock nut (D)

and adjust to the specified value by turning
the push rod.

Free play 10 to 15 mm

3. Check the fulcrum bolt and the bushing for

wear, the pedal for bending and the spring
for damage. Replace if necessary.