Clutch Assembly and/or Release Lever or Release Bearing

2.3L Engine

Removal

1. Lift clutch pedal to its uppermost position to disengage pawl and quadrant. Push quadrant forward, unhook cable from quadrant and allow it to slowly swing rearward. (Refer to Section 08-02).

    CAUTION: The clutch pedal must be lifted to disengage the adjusting mechanism during cable installation. Failure to do so will result in damage to the self-adjuster mechanism.

    CAUTION: Under no circumstances should a prying instrument such as a screwdriver or a pry bar be used to install or remove the cable from the quadrant.

2. Raise vehicle on a hoist. Refer to Section 00-02.

3. Remove hairpin clip and clevis pin from lower end of bellcrank.

4. Separate clevis from end of cable. Refer to Section 08-02.

5. Remove retaining clip and remove clutch cable from flywheel housing.

6. Remove starter electrical cable and starter motor from flywheel housing.

7. Remove bolts that secure flywheel housing-to-engine oil pan.

8. Remove transmission. Refer to Section 07-03

9. Remove bolts that attach housing to cylinder block. Move housing back just far enough to clear pressure plate, and remove.

10. Disconnect short cable from release lever by pushing cable and release lever boot approximately 12.7mm (1/2 inch) toward release bearing and pull cable rearward through hole in boot.

11. Remove release lever boot from flywheel housing.

12. Remove clutch release lever from housing by pulling it through window in housing until retainer spring is disengaged from pivot.

13. Remove release bearing from release lever.

14. Loosen six pressure plate cover retaining bolts evenly to release spring tension gradually and avoid distorting cover. If same pressure plate and cover are to be installed, mark cover and flywheel so that pressure plate can be installed in its original position. Remove pressure plate and clutch disc from flywheel.
    
    
    
    
    

    Item	Part Number	Description
    1A	N606062-S2	Bolt (5 Req'd)
    2	—	Rear Face of Block and Flywheel
    3	7K578	Dowel (3 Req'd)
    4	7548	Release Bearing Assy
    5	7515	Lever Assy
    6	7120	Pilot Bearing Installation with Seal Outboard (Toward Transmission)
    7	14303	Cable Assy
    8	N606062-S36	Bolt
    9	7550	Disc Assy
    10B	N602549-S2	Bolt (6 Req'd)
    11	7563	Assy
    12	6392	Housing Assy
    13	7050	Transmission Front Bearing Retainer
    14	34794-S2	Washer
    15	7B602	Ball
    16	6397	Dowel (2 Req'd)
    A		Tighten to 38-52 Nm (29-38 Lb-Ft)
    B		Tighten to 16-33 Nm (12-24 Lb-Ft)

Installation

1. Position clutch disc and pressure plate assembly on flywheel. Three dowel pins on flywheel must be properly aligned with pressure plate. Bent, damaged or missing dowels must be replaced. Start cover retaining bolts but do not tighten them. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.

2. Align clutch disc using proper alignment tool inserted in pilot bearing. To avoid pressure plate cover distortion, alternately tighten bolts a few turns at a time, until they are all tight. Then, tighten six pressure plate cover bolts to 16-33 Nm (12-24 lb-ft). Remove alignment tool.
   
   
   
   

3. Apply a light film of Premium Long-Life Grease C1AZ-19590-E (ESA -M1C75-B) or equivalent to:
   • Outside diameter of transmission front bearing retainer tube.
   • Release lever fork and anti-rattle spring where they contact the release bearing hub.
   • Release bearing surface that contacts pressure plate release fingers.
   • Release lever ball pivot and mating release lever pocket.

   Fill grease groove of released bearing hub with same grease. Clean all excess grease from inside bore of bearing hub. Otherwise, excess grease will be forced into spline by transmission input shaft bearing retainer, and will contaminate clutch disc.

4. Attach clutch release bearing to release lever.

5. Attach release lever and release bearing to flywheel housing.

6. Install release lever boot in housing with hole toward transmission.

7. Install short cable in hole, in release lever boot. Then, release short cable into keyhole slot in release lever, by pushing boot toward release bearing.

8. Inspect flywheel housing dowel holes for misalignment and wear.

9. Make certain that flywheel housing and cylinder block mounting surfaces are clean and that dowels are in good condition. Bent, damaged or missing dowels must be replaced.

10. Install flywheel housing to cylinder block and engine oil pan. Refer to Section 07-03. Tighten bolts to 38-52 Nm (29-38 lb-ft).

11. Install transmission-to-flywheel housing. Refer to Section 07-03.

12. Connect clutch cable to flywheel housing and connect retaining clip.

13. Place clevis over end fitting of cable and then with clevis in position, install clevis pin and hairpin clip.

14. Install starter motor and starter electrical cable.

15. Lower vehicle.

16. Install clutch cable assembly by lifting clutch pedal to disengage pawl and quadrant. Then, push quadrant forward and hook end of cable over rear of quadrant. Cycle clutch pedal several times to adjust cable. Refer to Section 08-02.

5.0L Engine

Removal

1. Lift clutch pedal to its uppermost position to disengage pawl and quadrant. Push quadrant forward, unhook cable from quadrant and allow it to slowly swing rearward. Refer to Cable Replacement, Section 08-02.

    CAUTION: The clutch pedal must be lifted to disengage the adjusting mechanism during cable installation. Failure to do so will result in damage to the self-adjuster mechanism.

    CAUTION: Under no circumstances should a prying instrument such as a screwdriver or a pry bar be used to install or remove the cable from quadrant.

2. Raise vehicle on a hoist. Refer to Section 00-02.

3. Remove dust shield.

4. Disconnect cable from release lever.

5. Remove retaining clip and remove clutch cable from flywheel housing.

6. Remove starter motor from flywheel housing.

7. Remove bolts that secure engine rear plate to front lower part of flywheel housing.

8. Remove transmission. Refer to Section 07-03. Remove bolts that attach housing to cylinder block. Move housing back just far enough to clear pressure plate and remove.

9. Remove clutch release lever from housing by pulling it through window in housing until retainer spring is disengaged from pivot.

10. Remove release bearing from release lever.

11. Loosen six pressure plate cover retaining bolts evenly to release spring tension gradually and avoid distorting cover. If same pressure plate and cover are to be installed, mark cover and flywheel so that pressure plate can be installed in its original position. Remove pressure plate and clutch disc from flywheel.
    
    
    
    
    

    Item	Part Number	Description
    1	6397	Dowel (2 Req'd)
    2	—	Rear Face of Block and Flywheel
    3	7K578	Dowel (3 Req'd)
    4	7548	Release Bearing Assy
    5	7515	Lever Assy
    6	7120	Pilot Bearing Assy (Install with Seal Toward Rear of Vehicle)
    7	7550	Disc Assy
    8	7563	Pressure Plate Assy
    9	7B602	Ball
    10	34794-S2	Washer
    11	34793-S2	Washer (6 Req'd)
    12	304781-S2	Bolt (2 Req'd)
    13	6392	Housing Assy
    14	7050	Transmission Front Bearing Retainer
    15	7513	Cover Assy (Installed After Cable Assy)
    16	55981-S36M	Bolt
    17A	304832-S2	Bolt (4 Req'd)
    18B	382087-S2	Bolt (6 Req'd)
    A		Tighten to 52-74 Nm (39-54 Lb-Ft)
    B		Tighten to 16-33 Nm (12-24 Lb-Ft)

Installation

1. Position clutch disc and pressure plate assembly on flywheel. Three dowel pins on flywheel must be properly aligned with pressure plate. Bent, damaged or missing dowels must be replaced. Start cover retaining bolts but do not tighten. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.

2. Align clutch disc using proper alignment tool inserted in pilot bearing. To avoid pressure plate cover distortion, alternately tighten bolts a few turns at a time, until they are all tight. Then tighten pressure plate cover bolts to 16-33 Nm (12-24 lb-ft). Remove alignment tool.

3. Apply a light film of Premium Long-Life Grease C1AZ-19590-E (ESA-M1C75-B) or equivalent to:
   • Outside diameter of transmission front bearing retainer.
   • Release lever fork and anti-rattle spring where they contact release bearing hub.
   • Release bearing surface that contacts pressure plate release fingers.
   • Release lever ball pivot, mating release lever pocket and cable ball pocket.

   Fill grease groove of release bearing hub with same grease. Clean all excess grease from inside bore of the bearing hub. Otherwise, excess grease will be forced onto spline by transmission input shaft bearing retainer, and will contaminate clutch disc.

4. Attach clutch release bearing to release lever.

5. Attach release lever and release bearing to flywheel housing.

6. Inspect flywheel housing dowel holes for misalignment and wear.

7. Make certain that flywheel housing and cylinder block mounting surfaces are clean and that dowels are in good condition. Bent, damaged or missing dowels must be replaced.

8. Install flywheel housing to cylinder block. Tighten bolts to 52-74 Nm (39-54 lb-ft).

9. Install transmission-to-flywheel housing. Refer to Section 07-03.

10. Install bolts that secure engine rear plate to front lower part of flywheel housing.

11. Connect clutch cable to flywheel housing and connect retaining clip.

12. Connect clutch cable to release lever. Install dust shield.

13. Install starter motor.

14. Lower vehicle.

15. Install clutch cable assembly by lifting clutch pedal to disengage pawl and quadrant. Then, push quadrant forward and hook end of cable over rear of quadrant. Cycle clutch pedal several times to adjust cable. Refer to Section 08-02.