| TUCSON(LM) >2012 > G 2.0 DOHC > 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.
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 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
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.