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TUCSON(LM) > 2011 > G 2.0 DOHC > Clutch System

Clutch System > General Information > Specifications

Specifications

Items Specifications
Engin.e type θ 2.0
Clutch operation method Hydraulic type
Clutch disc Type Single dry with diaphragm
Faling diameter(Outer × inner) 235 × 155mm(9.2520 × 6.1024 in.)
Clutch cover assembly Type Diaphragm spring strap
Clutch release cylinder inner diameter 20.64mm(0.8126 in.)
Clutch master cylinder inner diameter 15.87mm(0.6248 in.)

Service Standard
Standard value
Clutch disc thickness [When free] 8.0~8.6 mm (0.3150~0.3386 in.)
Distance between inner pad and clutch pedal 167 mm (6.5748 in.)
Clutch pedal free play 6~13 mm (0.2362~0.5118 in.)
Clutch pedal stroke 147~153 mm (5.7874~6.0236 in.)
Clutch pedal height 167 mm (6.5748 in.)
Limit
Clutch disc rivet sink 0.3 mm (0.0118 in.)
Diaphragm spring end height difference 0.5 mm (0.0197 in.)
Clutch replease cylinder clearance to piston 0.15 mm (0.0059 in.)
Clutch master cylinder clearance to piston 0.15 mm (0.0059 in.)

Tightening Torques
Item N.m kgf.m lb-ft
Clutch tube to clutch oil regulator 13 ~ 17 1.3 ~ 1.7 9.6 ~ 12.5
Clutch tube to clutch hose 13 ~ 17 1.3 ~ 1.7 9.6 ~ 12.5
Clutch release cylinder to clutch hose 25 ~ 35 2.5 ~ 3.5 18.4 ~ 25.8
Clutch release cylinder bleeder screw 12 ~ 20 1.2 ~ 2.0 8.9 ~ 14.5
Clutch cover 25 ~ 36 2.5 ~ 3.6 18 ~ 26
Ignition lock switch 8 ~ 10 0.8 ~ 1.0 5.9 ~ 7.4
Clutch pedal mounting 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8

Lubricants
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of clutch
CASMOLY L 9508 0.3~0.5g
release fork
Inner surface of clutch release cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L 9508 0.2g

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Inner surface of clutch master cylinder and outer

Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder push
CASMOLY L 9508 As required
rod

Clutch System > General Information > Special Service Tools

Special Service Tools

Tool (Number and name) Illustraion Use

09411-11000 Installation of the clutch disc.
Clutch disc guide

Clutch System > General Information > Troubleshooting

Troubleshooting

Trouble symptom Suspect area Remedy

Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace parts
speed during acceleration
• Insufficient vehicle speed Excessive wear of clutch disc facing Replace
• Lack of power during uphill driving Hardened clutch disc facing, or oil on surface Replace
Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise during Excessive pedal free play Adjust
shifting)
Hydraulic system fluid leaks, air trapping or Repair or replace parts
clogging
Unusual wear or corrosion of the clutch disc Replace
spline
Excessive vibration (distortion) of the clutch
Replace
disc
Clutch When the clutch is not Insufficient play of the clutch pedal Adjust
noisy used
Excessive wear of the clutch disc facing Replace
A noise is heard after the Unusual wear and/ or damage of the release Replace
clutch is disengaged bearing

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A noise is heard when the Insufficient grease on the sliding surface of the Repair
clutch is disengaged bearing sleeve
Improperly installed the clutch assembly or Repair
bearing
A noise is heard when the Damaged pilot bushing Replace
car suddenly rolled up with
the clutch partially
engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of Repair
clutch disc
Insufficient lubrication of the clutch release Repair
lever shaft
Insufficient lubrication of the front bearing
Repair
retainer
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive or Inspect the clutch disc
lining broken
Spline on the input shaft or clutch disc dirty or Repair as necessary
burred
Faulty of the clutch pressure plate Replace the clutch cover
Clutch slips Insufficient of the clutch pedal free play Adjust the pdal free play
Clogged of the hydraulic system Repair or replace parts
Clutch disc lining oily or worn out Inspect the clutch disc
Faulty of the pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent the clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Loose the engine mounts Repair as necessary
Clutch noisy Replace the clutch pedal
Damaged the clutch pedal bushing
bushing
Loose part inside housing Repair as necessary
Worn or dirty release bearing Replace the replease bearing
Sticking release fork or linkage Repair as necessary

Clutch System > Clutch System > Repair procedures

Service Adjustment Procedure

Clutch Pedal Inspection And Adjustment

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1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the distance between inner
pad and clutch pedal.

Standard value:
(A) 243~247 mm (9.5669~9.7244 in.)
(B) 167mm (6.5748 in.)

2. Confirm that the measuring values of the free play of the clutch pedal and the distance between the clutch pedal
which is disconnected from the master cylinder and the floor board, are within the standard values.

Free play of clutch pedal (C):

6~13 mm (0.2362~0.5118 in.)
Distance between clutch pedal and toe board (D):
39 mm (1.5354 in.)

3. If the clutch pedal's free play and the distance between the clutch pedal which is disconnected from the master
cylinder and the floor board, do not meet with the standard values, it may be the cause, either air in the hydraulic
system or a faulty the clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.

Bleeding

Use the specified fluid. Avoid mixing different brands of fluid.

Specified fluid: SAE J1703 (DOT 3 or DOT 4)

1. Loosen the bleeder screw(B) at the clutch release cylinder(A).

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2. Pump the clutch pedal slowly until all air is expelled.

3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.

The rapidly-repeated operation of the clutch pedal in B-C range may disrupt the release cylinder's position.
During the bleeding operation, press the clutch pedal to the floor after it returns to the "A" point.

Clutch System > Clutch System > Clutch Cover And Disc > Components and Components
Location
Componenets

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1. Clutch release lever 5. Clutch cover assembly

2. Bushing 6. Clutch disc
3. Clutch release fork 7. Clutch release bearing
4. Bushing

Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
Inspection

Clutch cover assembly

1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.

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3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

Clutch disc
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and
replace the clutch disc if defective.
2. Measure the thickness of the disc when free.

Limit : 0.3 mm (0.0118 in.)

3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

Clutch release bearing

The release bearing is packed with grease. Do not use cleaning solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for
wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

Clutch release fork

Removal
1. Remove the transaxle assembly.(See 'MT' group - 'Manual Transaxle')
2. Remove the release bearing.
3. Remove the clutch cover and the disk from the engine.

• Insert the special tool (09411-11000) into the spline hole to support the clutch disk when removing the clutch
cover.
• Do not use solvent to clean the clutch disk and the release bearing.

4. Remove the bushing and the release fork assembly.

Installation
1. Grease where is 10mm from the end of the transaxle's input shaft, before installing the clutch disk and cover

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assembly.

Grease: CASMOLY L9508

2. Install the clutch disc assembly to the flywheel using the special tool (09411-11000).
3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts three steps at a time in a star
pattern.

Tightening torque :
Clutch cover bolt:
25~36 N.m(2.5~3.6 kgf.m, 18~26 lb-ft)

4. Align the bearing (A) to the release fork (B) and then install it to the sleeve of the housing.

Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve, contact point of the release fork (B) and
the bushing inner surface (C).

Groove of bearing sleeve : 0.5~1.0g

Contacting part of release fork : 0.3~0.5g
Bushing's neck : 0.8~1.2g

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5. Install the release lever to the release fork.

6. Install the transaxle assembly to the engine.

If the transaxle assembly is installed to the engine without performing this step, the release bearing can be
separated, as the release fork rotates freely.

Clutch System > Clutch System > Clutch Pedal > Components and Components Location
Components

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1. Reverse hose 6. Clutch switch

2. Master cylinder 7. Clutch arm
3. Siller 8. Pedal pad
4. Member assembly 9. Ignition lock switch
5. Turn over spring 10. Stopper

Clutch System > Clutch System > Clutch Pedal > Repair procedures
Inspection
1. Check the pedal shaft and bushing for wear.

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2. Check the clutch pedal for bending or torsion.

3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.

Ignition lock switch inspection

Returing Test Of Clutch Pedal

Deformation of pedal pad must be MAX. 5mm after repeating the test 20 times (sudden return from full stroke).

Adjustment

• Check for the ignition lock switch.

In case of clutch lock system vehicle, there is an additional switch.
• Before adjusting, remove the driver's floor seat.

1. After loosening the ignition lock switch nut, move it back until it has no contact with the clutch pedal arm.(In case of
clutch lock system vehicle, repeat this step with its additional ignition lock switch).
2. Check for the specification below.

Clutch pedal stroke : 147~153 mm (5.7874~6.0236 in.)

Clutch pedal free play : 6~13 mm (0.2362~0.5118 in.)
Distance between the inner pad and clutch pedal : 167 mm (6.5748 in.)

3. (Clutch lock system vehicle)

Fix the additional ignition lock switch when its signal is ON pressing the pedal slowly 112~118 mm (4.4~4.6 in.).
Tighten the fixing nut with specification.

Tightening torque :
8~10N.m (0.8~1.0kgf.m, 5.9~7.4lb-ft)

Replacement

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1. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
2. Disconnect the clutch tube (B) from the master cylinder.

3. Disconnect the two ignition lock switch connectors (C).

4. Remove the clutch pedal mounting bolts (A-3ea) and the bracket mounting nuts (B-1ea.)

Tightening torque :
16.7~25.5N.m (1.7~2.6kgf.m, 12.3~18.8lb-ft)

5. Installation is resverse of removal.

Clutch System > Clutch System > Clutch Master Cylinder > Components and Components
Location
Components

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1. Reverse hose 6. Clutch switch

2. Master cylinder 7. Clutch arm
3. Siller 8. Pedal pad
4. Member assembly 9. Ignition lock switch
5. Turn over spring 10. Stopper

Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
Removal

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Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off
immediately with water.

1. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).

2. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.
3. Disconnect the clutch tube (B) from the master cylinder.

4. Remove the clutch master cylinder by turning it clockwise.(A)

Installation
1. Installation is the reverse of removal.

• Perform the bleeding air procedure in the clutch release cylinder.

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Adjustment
Clutch release cylinder Air Bleeding Procedure

Use the specified fluid. Avoid mixing different brands of fluid.

Specified fluid: SAE J1703 (DOT 3 or DOT 4)

1. After disconnecting a cap(A) from the clutch release cylinder air bleeder, insert a vinyl hose(B) in the plug.

2. Loosening the plug screw, press and release the clutch pedal about 10 times.
3. After pressing the clutch pedal 3 times more, loosen the plug(A) and retighten it with the pedal pressed. Raise it
again, then.

Tightening torque :
11.8~19.6 N.m (1.2~2.0 kgf.m, 8.7~14.5 lb-ft)

4. Repeat the step 3 two or three times. (until there is no bubble in the fluid)
5. Refill the clutch master cylinder with the specified fluid.

• During the bleeding operation, press the clutch pedal to the floor after it returns to the "A" point.
• The rapidly-repeated operation of the clutch pedal in B-C range may disrupt the release cylinder's position.

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Clutch System > Clutch System > Clutch Release Cylinder > Components and
Components Location
Components

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1. Gasket 7. Boot
2. Clutch hose 8. Push rod
3. Bleeder screw 9. Union bolt
4. Recease cylinder 10. Valve plate
5. Return spring 11. Valve spring
6. Piston 12. Cotter pin

Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
Removal
1. Drain the fluid from the bleeding plug(A).

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2. Clamp the clutch hose between the clutch release cylinder and the clutch tube.
3. Remove the clutch release cylinder loosening the mounting bolt.
4. Install a new clutch release cylinder.

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