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wj4_5c0
SECTION : 5C
CLUTCH
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
. . . . . . . . . . . . . . . . . . . . . . . . .
FASTENER TIGHTENING
SPECIFICATIONS
5C0–1
CLUTCH PEDAL
ADJUSTMENT (HYDRAULIC)
. . . . . . . . . . .
5C0–15
. . . . . . . . . . . . . . . . . . . . . .
5C0–1
CLUTCH RELEASE POINT
ADJUSTMENT (HYDRAULIC)
. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS TABLE
5C0–2
. . . . . . . . . . .
5C0–17
. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER
CYLINDER ASSEMBLY
5C0–17
. . . . . . . . . . . . . . . . . .
5C0–2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH OPERATION
5C0–2
. . . . . . . . . . . . . . . .
5C0–17
. . . . . . . . . . . . . . . . . . . .
5C0–2
CLUTCH RELEASE
CYLINDER ASSEMBLY
. . . . . . . . . . . . . . . .
5C0–20
. . . . . . . . . . . . . . . . . . .
HYDRAULIC CLUTCH COMPONENTS
5C0–4
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER
5C0–21
. . . . .
5C0–4
. . . . . . . . . . . .
5C0–21
MAINTENANCE AND REPAIR
. . . . . . . . . . . . . .
5C0–7
CLUTCH RELEASE CYLINDER
. . . . . . . . . . .
5C0–23
ON–VEHICLE SERVICE
. . . . . . . . . . . . . . . . . . . .
5C0–7
GENERAL DESCRIPTION AND
SYSTEM OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL POSITION SWITCH
5C0–7
. . . . . . . . . . . . . . . . . . .
5C0–25
. . . . . . .
5C0–9
DRIVING MEMBERS
. . . . . . . . . . . . . . . . . . . .
5C0–25
CLUTCH DISC AND RELATED
COMPONENTS
. . . . . . . . . . . . . . . . . . . . .
OPERATING MEMBERS
5C0–25
. . . . . . . . . . . . . . . . . . . . . . .
5C0–10
. . . . . . . . . . . . . . . . .
5C0–25
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
N
m
Lb–Ft
Lb–In
Clutch Fork–to–Release Lever Shaft Bolt
35
26
Clutch Master Cylinder Locknuts
22
18
Clutch Pedal Nut
18
13
Pressure Plate–to–Flywheel Bolt
15
11
Release Bearing Guide Sleeve Bolts
5
45
Release Cylinder Bolts
60
44
SPECIFICATIONS
SPECIAL TOOLS
AIR BLEEDING
DIAGNOSIS
COMPONENT LOCATOR
UNIT REPAIR
CLUTCH PEDAL
DRIVEN MEMBERS
84500039.006.png
5C0 – 2 I CLUTCH
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–36547
Input Shaft Seal
Installer
J–42474
Clutch Arbor
DIAGNOSIS
CLUTCH OPERATION
Fails to Release
Checks Action
DEFINITION: When the pedal is pressed to the floor, the shift lever does not move freely in and out of reverse gear.
Check for a loose linkage.
Repair or replace loose linkage, if necessary.
Check for a damaged clutch disc.
Replace the damaged clutch disc.
Check for an improperly installed fork shaft.
Remove and properly reinstall the fork shaft. Very lightly
lubricate the fork fingers at the release bearing with wheel
bearing grease.
Check for the clutch disc hub binding on the input shaft
splines.
Repair or replace the clutch disc hub.
Check for a warped or bent clutch disc.
Replace the warped or bent clutch disc.
Slipping
Checks Action
Check for the driver improperly operating the vehicle. Correct the driver’s operation of the vehicle as necessary.
Check for an oil–soaked clutch disc. Correct the leak at its source and install a new clutch disc.
Check for a worn facing or a facing torn from the disc. Replace the worn disc with a new disc.
Check for a warped pressure plate or a warped flywheel. Replace the warped pressure plate or the warped fly-
wheel.
Check for a weak diaphragm spring.
Replace the pressure plate.
Check for a driven plate that is not seated.
Start the engine 30 to 40 times. Do not overheat the en-
gine.
Check for a driven plate that is overheated.
Allow the driven plate to cool.
DAEWOO V–121 BL4
84500039.007.png 84500039.008.png 84500039.009.png
CLUTCH 5C0 – 3
Grabbing (Chattering)
Checks
Action
Check for a burned or a glazed facing caused by oil on the
facing.
Correct the leak at its source and install a new clutch disc.
Check for worn splines on the input shaft. Replace the worn input shaft.
Check for a warped pressure plate or a warped flywheel. Replace the warped pressure plate or the warped fly-
wheel.
Check for burned or smeared resin on the flywheel or the
pressure plate.
Sand off the burned or smeared resin if it is superficial.
Replace any burned or heat–checked parts.
Rattling (Transaxle Click)
Checks
Action
Check for weak retracting springs.
Replace the pressure plate.
Check for a loose release fork.
Remove and reinstall the release fork properly.
Check for oil in the driven plate damper.
Correct the cause of the oil leak and replace the driven
disc.
Check for a damaged driven plate damper spring.
Replace the driven disc.
Release Bearing Noise with Clutch Fully Engaged
Checks
Action
Check for the driver improperly operating the vehicle.
Correct the driver’s operation of the vehicle as necessary.
Check for a binding release bearing.
Clean and re–lubricate the release bearing. Inspect the re-
lease bearing for burrs and nicks.
Check for an improperly installed release lever.
Remove and reinstall the release lever properly.
Check for a weak linkage return spring.
Replace the weak linkage return spring.
Noisy
Checks
Action
Check for a worn release bearing.
Replace the worn release bearing.
Check for an improperly installed release lever.
Remove and properly reinstall the fork shaft. Very lightly
lubricate the fork fingers at the release bearing with wheel
bearing grease.
Pedal Stays on Floor When Disengaged
Checks
Action
Check for binding in the linkage or the release bearing.
Lubricate and free–up the binding linkage or the release
bearing.
Check for weak pressure plate springs.
Replace the pressure plate.
Hard Pedal Effort
Checks
Action
Check for binding in the linkage.
Lubricate and free–up the binding linkage.
Check for a worn driven plate.
Replace the worn driven plate.
DAEWOO V–121 BL4
84500039.001.png 84500039.002.png 84500039.003.png
5C0 – 4 I CLUTCH
COMPONENT LOCATOR
HYDRAULIC CLUTCH COMPONENTS
1. ReleaseLever
2. Pipe
3. Clip
4. Clamp
5. Hose
6. Bolt
7. Bolt
8. Bolt
9. SpringWasher
10. Release Cylinder Bracket
11. Release Cylinder
12. Air Bleeder
13. Bolt
14. Copper Washer
15. Bolt
16. O–ring
17. Input Shaft Seal
18. Bearing Guide Sleeve
19. Release Bearing
20. Fork
21. Bushing
22. Bolt
23. Bolt
24. Pressure Plate
25. Clutch Disc
26. Nut
27. Spring Washer
28. Bushing
DAEWOO V–121 BL4
84500039.004.png
CLUTCH 5C0 – 5
1. ReservoirCap
2. Clutch/BrakeReservoir
3. SpringClamps
4. ReservoirHose
5. Nut
6. MasterCylinder
7. Gasket
8. Piston Rod Bolt
9. Nut
10. Washer
11. Clutch Pedal Bushing
12. Clutch Pedal
13. Clutch Pedal Buffer
14. Nut
15. Bolt
16. Return Spring
17. Clutch Pedal Bushing
18. Pedal Mounting Shaft
19. Clutch Pedal Pad
20. Locking Washer
21. Clutch Pedal Bushing
22. Hydraulic Clutch Pipe
23. Clip
24. Clutch Pedal Position Switch
25. Clutch Pedal Position Switch Adjusting Screw
DAEWOO V–121 BL4
84500039.005.png

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