Clutch Disc: Service and Repair - JustAnswer · 2017. 2. 26. · CLUTCH RELEASE FORK If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly

2003 Hyundai Tiburon V6-2.7L Copyright © 2013, ALLDATA 10.52 Page 1

Clutch Disc: Service and RepairCLUTCH COVER AND DISC

COMPONENTS

REMOVAL 1. Drain the clutch fluid and transaxle gear oil.2. Remove the transaxle assembly.3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling.4. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.

5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

CAUTION: DO NOT clean the clutch disc or release bearing with cleaning solvent.

INSPECTION CLUTCH COVER ASSEMBLY 1. Check the diaphragm spring end for wear and uneven height.

Replace if wear is evident or height difference exceeds the limit.Limit: 0.5 mm (0.012 inch))

2. Check the pressure plate surface for wear, cracks and color change.


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 rivet sink and replace the clutch disc if it is out of specificationLimit: 1.1 mm (0.044 inch))

3. Check for 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.5. If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

CAUTION: 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 If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.

INSTALLATION

1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.

CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage andjudder.


2. Apply multipurpose grease into the groove of the release bearing.Grease: CASMOLY L9508

3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.Grease: CASMOLY L9508

4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease hasbeen removed.

5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.Grease: CASMOLY L9508

CAUTION: Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.

6. Using the special tool (09411-25000), install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having themanufactures stamp is towards the pressure plate side.

7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.8. Diagonally tighten the bolts 15 - 22 Nm (150 - 220 kg.cm, 11 - 15 ft. lbs.) .9. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.

Remove the special tool.10. Install the transaxle.


11. Adjust the clutch pedal free-play.


Clutch Disc: Technical Service BulletinsM/T - Dual Mass Flywheel/Clutch Installation ProcedureGroup: TRANSAXLE

Number: 02-40-025

Date: OCTOBER, 2002

Model: 2003 TIBURON

Subject2003 TIBURON DUAL MASS FLYWHEEL AND CLUTCH DISC ASSEMBLY INSTALLATION PROCEDURE

DESCRIPTION:

The 2003 MY 2.7L Tiburon vehicle equipped with the 6-speed manual transaxle employs a dual mass flywheel system. The 2003 Tiburon Shop Manualdoes not show the clutch disc assembly with the dual mass flywheel. This bulletin provides information about how to assemble these components.

NOTE:Although it is possible to assemble the clutch disc with either side facing the flywheel surface, only the assembly of these two parts shown in thisbulletin is correct.

PARTS ASSEMBLY:

1. Attach the dual mass flywheel to the engine crankshaft assembly.

2. Identify the clutch disc flange side and the collar side as shown.

3. Install the collar side of the clutch disc on the dual mass flywheel surface so that the flange side is facing the pressure plate side as shown.


4. Attach the pressure plate to the dual mass flywheel and complete assembly of the remaining components per the Shop Manual procedures.


Flywheel: SpecificationsFLYWHEEL 2.7L

Drive plate and adaptor plate bolt ...................................................................................................................... 73-77 Nm (730-770 kg-cm, 53-56 ft. lbs.)


Manual Transmission/Transaxle: Service and RepairRemoval and InstallationMANUAL TRANSAXLE SYSTEM

REMOVAL

1. Remove the engine cover.

2. Remove the battery terminal.

3. Remove the air duct.

4. Remove the battery tray.5. Remove the air cleaner.


a. Upper

b. Lower

6. Remove the back-up lamp switch.

7. After removing the CKP sensor, 02 sensor and oil pressure switch wiring bracket, separate the connectors.


8. Remove the brake fluid leveling sensor connector.9. Remove the speedometer driven gear connector.

10. Remove the clutch release cylinder mounting bolt.

11. Remove the cotter pin of the shift cable (transaxle side).12. Remove the cotter pin of the select cable. (transaxle side)

13. Remove the clip of the shift cable (transaxle side).


14. Remove the clip of the select cable (transaxle side).

15. Separate the steering column shaft joint.

16. Separate the power steering oil pump hose.

NOTE: Be careful not to leak after separating.

17. Separate the hose after removing the clip of the power steering return hose.


18. Remove the upper connecting transaxle bolt.

19. Separate the start motor.20. Install the engine support fixture.

21. After removing the tire, remove the caliper.

22. Remove the transaxle side cover.


23. Remove the transaxle side under cover.

24. Separate the tie rod end.

25. Remove the wheel speed sensor and the knuckle mounting bolt.

26. Drain the oil.27. Remove the transaxle mounting bracket.


a. Insulator bolt

b. Body side mounting bolt (Upper)

c. Body side mounting bolt (Side)

d. Transaxle side mounting bolt.28. Remove the front roll stopper.


a. Insulator bolt

b. Stopper bolt (Upper)

c. Stopper bolt (Lower)29. Remove the rear roll stopper.

a. Insulator bolt


b. Stopper bolt30. Remove the drive shaft.

31. Remove the front muffler.

32. Remove the sub frame mounting bolt.

33. Install the transaxle jack.


34. Remove the transaxle lower mounting bolt to the engine.35. Remove the transaxle assembly.

INSTALLATION Installation is the reverse of the removal.

Documents

Clutch Disc: Service and Repair - JustAnswer · 2017. 2. 26. · CLUTCH RELEASE FORK If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly