User Guide

EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
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Good Fitting Practice ...
Installing your new EXEDY/Daikin Clutch
1. Getting it right the rst time. It is vital to diagnose the cause of clutch malfunction before
clutch replacement, i.e. check hydraulic system - bearing free travel - clutch cable, oil leaks and
check for any signs of red dust when old clutch is being removed. Any or all of these problems
must be corrected before installing new clutch.
2. Ensure clutch supplied is correct for application. If you’re unsure, consult your EXEDY/Daikin
Clutch Catalogue or your supplier, as tting a clutch to the wrong application will void the
warranty.
3. Flywheel must be resurfaced or warranty void and check pilot bearing or bush and replace
if necessary.
4. Before tting, check clutch for any shipping damage. Next, check that clutch disc slides freely
on gearbox shaft and then clean shaft splines. Lightly grease the shaft splines with high
melting point grease. Always ensure bell housing is degreased and is free of dust and that
bres from the worn clutch are removed.
5. Check the clutch release fork for cracks, check the clutch cable for stretch signs and
check the release bearing gear box quill/gear box main drive nose cone bearing slide for
any wear. Always lightly grease this part where the bearing slides. This will allow smooth
sliding of the bearing carrier. Always work the fork forward and backwards after installing
bearing on the quill.
6. Place the clutch cover pressure plate assembly over the clutch disc, after checking that the
disc is the right way around and the hub section of the disc does not foul on the casting of
the clutch cover assembly or the ywheel. A suitable clutch aligning tool will ensure correct
alignment, assist in ease of installation and avoid spline damage. (Burrs on splines are a major
cause of dicult gear disengagement). Ensure pressure plate dowels are aligned to the cover.
Tighten bolts is a diagonal pattern and never use air tools to install a clutch cover assembly.
7. Re-t gear box, taking care not to bend the clutch disc. Never hang the gear box o the clutch
disc or use any force to align gear box shaft.
8. Check all bell housing dowels are in correct position and tighten bell housing bolts.
Ensure there is no dirt or foreign material between the mating surfaces of the engine
and the bell housing.
9. Perform any clutch adjustment only to vehicle manufacturer’s specications.
10. Always check the clutch cable if you are unable to obtain disengagement when a new clutch is
tted. Start o your check process be replacing the cable and checking hydraulic system.
11. Road test vehicle and never abuse a newly tted clutch. Allow 1000mi run in and
always adjust free travel on your new clutch at 1000mi and 3000mi. Thereafter adjust at
every 10,000 mi.
WARNING: Do not use EXEDY/Daikin clutches in any situation where engine RPM’s may
exceed manufacturer’s specications — a pressure plate could explode
unexpectedly causing serious injury or death to vehicle occupants and
bystanders. Clutch cover and bell housing will not protect against exploding
pressure plates. Refer Application Catalog correct tment.
Check Before Replacing
How To Get It Right The First Time
Noise Driveable
Page 18 Causes
and Solutions
Idling
Starting
Driving
Others
•Not depressing clutch pedal
•Depressing clutch pedal
•Engagement
•Open throttle
(Acceleration)
•Engagement
•Acceleration,
Deceleration
•Depressing
clutch pedal
5A, 5B, 5C, 5E
5C, 5D, 5F
5G
5H
5I
5J
Observe the sure signs of a worn clutch when removing.
1. Red dust.
2. Broken side plates or springs
3. Damaged torque stopper pins
4. Clutch disc with broken segments and broken friction material.
5. Broken or worn release bearing quills/gear box nose cone bearing slide.