Clutch Cover And Disc: Installation

CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and vibration (shudder).

Fig 1: Applying Grease To Splines Of Clutch Disc

Courtesy of KIA MOTORS AMERICA, INC.

Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508
Install the clutch disc assembly to the flywheel using the special tool (09411-25000).
Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.
Tightening torque

Clutch cover bolt:

15 ~ 22 Nm (150~220 kg.cm, 10~16 lb.ft)

Fig 2: Clutch Cover Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve and contact point of the release fork.

Fig 3: Aligning Bearing To Release Fork

Courtesy of KIA MOTORS AMERICA, INC.

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

Fig 4: Installing Release Lever To Release Fork
Courtesy of KIA MOTORS AMERICA, INC.
Install the transaxle assembly to the engine.
CAUTION: If the transaxle assembly is installed to the engine without performing step 7, the release bearing can be separated, as the release fork rotates freely.
After finishing step 6, push the release lever to the arrow mark. If there is a click sound, the release bearing and clutch cover are aligned correctly. If the assembly does not snap into place, start with step 1 again. Release lever operating range is 3° or less. If the range is over 3°, the release bearing and clutch cover are not aligned correctly. Push the release lever to the arrow mark one more time.

Fig 5: Moving Release Lever To Check Release Bearing & Clutch Cover Alignment
Courtesy of KIA MOTORS AMERICA, INC.