DAEWOO T-100 BL3

SECTION 5C
&/87&+
CAUTION: Disconnect the negative battery cabIe before removing or instaIIing any eIectricaI unit or when a
tooI or equipment couId easiIy come in contact with exposed eIectricaI terminaIs. Disconnecting this cabIe
wiII heIp prevent personaI injury and damage to the vehicIe. The ignition must aIso be in LOCK unIess
otherwise noted.
TABLE OF CONTENTS
Specifications 5C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C-1 . . . . . . . . . . .
SpeciaI TooIs 5C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpeciaI TooIs TabIe 5C-2 . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 5C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIutch Operation 5C-2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 5C-4 . . . . . . . . . . . . . . . . . . . . . . . .
HydrauIic CIutch Components 5C-4 . . . . . . . . . . . . . . .
Maintenance and Repair 5C-7 . . . . . . . . . . . . . . . . . . . .
On-VehicIe Service 5C-7 . . . . . . . . . . . . . . . . . . . . . . . . . .
CIutch PedaI 5C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIutch Disc and ReIated Components 5C-9 . . . . . . . .
CIutch PedaI Adjustment (HydrauIic) 5C-14 . . . . . . . .
CIutch ReIease Point Adjustment
(HydrauIic) 5C-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air BIeeding 5C-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIutch Master CyIinder AssembIy 5C-16 . . . . . . . . . . .
CIutch ReIease CyIinder AssembIy 5C-19 . . . . . . . . . .
Unit Repair 5C-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIutch Master CyIinder 5C-20 . . . . . . . . . . . . . . . . . . . .
CIutch ReIease CyIinder 5C-22 . . . . . . . . . . . . . . . . . . .
GeneraI Description and System
Operation 5C-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Members 5C-24 . . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C-24 . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C-24 . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
AppIication N:m Lb-Ft Lb-In
CIutch Fork to ReIease Lever Shaft BoIt 35 26 -
CIutch Master CyIinder Locknuts 22 18 -
CIutch PedaI Nut 18 13 -
Pressure PIate to FIywheeI BoIt 15 11 -
ReIease Bearing Guide SIeeve BoIts 5 - 45
ReIease CyIinder BoIts 60 44 -
5C-- 2 CLUTCH
DAEWOO T-100 BL3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
A103C009
J-36547
Input Shaft SeaI
InstaIIer
A103C045
J-42474
CIutch Arbor
DIAGNOSIS
CLUTCH OPERATION
FaiIs to ReIease
Checks Action
DEFINITION: When the pedaI is pressed to the fIoor, the shift Iever does not move freeIy in and out of reverse
gear.
Check for a Ioose Iinkage. Repair or repIace Ioose Iinkage, if necessary.
Check for a damaged cIutch disc. RepIace the damaged cIutch disc.
Check for an improperIy instaIIed fork shaft. Remove and properIy reinstaII the fork shaft. Very
IightIy Iubricate the fork fingers at the reIease bearing
with wheeI bearing grease.
Check for the cIutch disc hub binding on the input
shaft spIines.
Repair or repIace the cIutch disc hub.
Check for a warped or bent cIutch disc. RepIace the warped or bent cIutch disc.
SIipping
Checks Action
Check for the driver improperIy operating the vehicIe. Correct the driver's operation of the vehicIe as
necessary.
Check for an oiI-soaked cIutch disc. Correct the Ieak at its source and instaII a new cIutch
disc.
Check for a worn facing or a facing torn from the disc. RepIace the worn disc with a new disc.
Check for a warped pressure pIate or a warped
fIywheeI.
RepIace the warped pressure pIate or the warped
fIywheeI.
Check for a weak diaphragm spring. RepIace the pressure pIate.
Check for a driven pIate that is not seated. Start the engine 30 to 40 times. Do not overheat the
engine.
Check for a driven pIate that is overheated. AIIow the driven pIate to cooI.
CLUTCH 5C-- 3
DAEWOO T-100 BL3
Grabbing (Chattering)
Checks Action
Check for a burned or a gIazed facing caused by oiI on
the facing.
Correct the Ieak at its source and instaII a new cIutch
disc.
Check for worn spIines on the input shaft. RepIace the worn input shaft.
Check for a warped pressure pIate or a warped
fIywheeI.
RepIace the warped pressure pIate or the warped
fIywheeI.
Check for burned or smeared resin on the fIywheeI or
the pressure pIate.
Sand off the burned or smeared resin if it is superficiaI.
RepIace any burned or heat-checked parts.
RattIing (TransaxIe CIick)
Checks Action
Check for weak retracting springs. RepIace the pressure pIate.
Check for a Ioose reIease fork. Remove and reinstaII the reIease fork properIy.
Check for oiI in the driven pIate damper. Correct the cause of the oiI Ieak and repIace the driv-
en disc.
Check for a damaged driven pIate damper spring. RepIace the driven disc.
ReIease Bearing Noise with CIutch FuIIy Engaged
Checks Action
Check for the driver improperIy operating the vehicIe. Correct the driver's operation of the vehicIe as
necessary.
Check for a binding reIease bearing. CIean and re-Iubricate the reIease bearing. Inspect
the reIease bearing for burrs and nicks.
Check for an improperIy instaIIed reIease Iever. Remove and reinstaII the reIease Iever properIy.
Check for a weak Iinkage return spring. RepIace the weak Iinkage return spring.
Noisy
Checks Action
Check for a worn reIease bearing. RepIace the worn reIease bearing.
Check for an improperIy instaIIed reIease Iever. Remove and properIy reinstaII the fork shaft. Very
IightIy Iubricate the fork fingers at the reIease bearing
with wheeI bearing grease.
PedaI Stays on FIoor When Disengaged
Checks Action
Check for binding in the Iinkage or the reIease bearing. Lubricate and free-up the binding Iinkage or the re-
Iease bearing.
Check for weak pressure pIate springs. RepIace the pressure pIate.
Hard PedaI Effort
Checks Action
Check for binding in the Iinkage. Lubricate and free-up the binding Iinkage.
Check for a worn driven pIate. RepIace the worn driven pIate.
5C-- 4 CLUTCH
DAEWOO T-100 BL3
COMPONENT LOCATOR
HYDRAULIC CLUTCH COMPONENTS
A103C001
1 ReIease Lever
2 Pipe
3 CIip
4 CIamp
5 Hose
6 BoIt
7 BoIt
8 BoIt
9 Spring Washer
10 ReIease CyIinder Bracket
11 ReIease CyIinder
12 Air BIeeder
13 BoIt
14 Copper Washer
15 BoIt
16 O-ring
17 Input Shaft SeaI
18 Bearing Guide SIeeve
19 ReIease Bearing
20 Fork
21 Bushing
22 BoIt
23 BoIt
24 Pressure PIate
25 CIutch Disc
26 Nut
27 Spring Washer
28 Bushing
CLUTCH 5C-- 5
DAEWOO T-100 BL3
A103C035
1 Reservoir Cap
2 CIutch/Brake Reservoir
3 Spring CIamps
4 Reservoir Hose
5 Nut
6 Master CyIinder
7 Gasket
8 Piston Rod BoIt
9 Nut
10 Washer
11 CIutch PedaI Bushing
12 CIutch PedaI
13 CIutch PedaI Buffer
14 Nut
15 BoIt
16 Return Spring
17 CIutch PedaI Bushing
18 PedaI Mounting Shaft
19 CIutch PedaI Pad
20 Locking Washer
21 CIutch PedaI Bushing
22 HydrauIic CIutch Pipe
23 CIip
5C-- 6 CLUTCH
DAEWOO T-100 BL3
A103C003
1 FIywheeI
2 CIutch Disc
3 Pressure PIate
4 ReIease Bearing
CLUTCH 5C-- 7
DAEWOO T-100 BL3
A103C049
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
CLUTCH PEDAL
RemovaI Procedure
1. Disconnect the negative battery cabIe.
2. Disconnect the return spring from the mount brace.
A103C036
3. Remove the nut, the washer, and the pedaI mounting
shaft.
A103C037
4. Remove the Iocking washer and the piston rod boIt.
5. Remove the cIutch pedaI with the return spring from
the vehicIe.
5C-- 8 CLUTCH
DAEWOO T-100 BL3
A103C037
InstaIIation Procedure
1. InstaII the cIutch pedaI with the return spring to the
mount brace.
2. Coat the piston rod boIt with muIti-purpose grease.
3. InstaII the piston rod boIt and the Iocking washer.
A103C036
4. Coat the pedaI mounting shaft with muIti-purpose
grease.
5. InstaII the pedaI mounting shaft, the washer, and the
nut.
Tighten
Tighten the nut to 18 N:m (13 Ib-ft).
A103C049
6. Connect the return spring to the mount brace.
7. Connect the negative battery cabIe.
CLUTCH 5C-- 9
DAEWOO T-100 BL3
A103C025
CLUTCH DISC AND RELATED
COMPONENTS
RemovaI Procedure
1. Disconnect the negative battery cabIe.
2. Raise and suitabIy support the vehicIe.
3. Remove the Ieft front wheeI. Refer to Section 2E,
Tires and WheeIs.
4. Remove the engine under covers. Refer to Section
9N, Frame and Underbody.
5. Remove the transaxIe fromthe vehicIe. Refer toSec-
tion 5B, Five-Speed ManuaI TransaxIe.
6. Remove the pressure pIate boIts and the pressure
pIate. Support the pressure pIate when you remove
the Iast boIt.
A103C026
7. Remove the cIutch disc.
A103C027
8. Remove the reIease fork boIt.
5C-- 10 CLUTCH
DAEWOO T-100 BL3
A103C028
9. PuII the cIutch reIease shaft upward, out of the
transaxIe.
A103C029
10. Remove the fork and the reIease bearing from the
reIease bearing guide sIeeve.
A103C033
11. Remove the reIease Iever shaft bushings.
CLUTCH 5C-- 11
DAEWOO T-100 BL3
A103C030
12. Remove the boIts and the reIease bearing guide
sIeeve.
A103C031
13. Remove the input shaft seaI from the reIease bear-
ing guide sIeeve.
A103C032
14. Remove the O-ring fromthe groove in the transaxIe
case.
5C-- 12 CLUTCH
DAEWOO T-100 BL3
A103C033
InstaIIation Procedure
TooIs Required
J-36547 Input Shaft SeaI InstaIIer
J-42474 CIutch Arbor
1. InstaII the O-ring into the groove in the case.
A103C034
2. InstaII the input shaft seaI into the reIease bearing
guide sIeeve. Use input shaft seaI instaIIer J-36547
with a hammer.
A103C030
3. InstaII the reIease bearingguide sIeeve and the boIts.
Tighten
Tighten the boIts to 5 N:m (45 Ib-in).
4. Coat the sIeeve surface with muIti-purpose grease.
CLUTCH 5C-- 13
DAEWOO T-100 BL3
A103C033
5. InstaII the reIease Iever shaft bushings. Coat the
bushing bores with muIti-purpose grease.
A103C029
6. Coat the reIease bearing bore with muIti-purpose
grease.
7. InstaII the reIease bearing, with the cIutch fork, onto
the reIease bearing guide sIeeve.
A103C028
8. InstaII the reIease Iever shaft from the top of the
transaxIe. Guide the shaft through the cIutch fork.
5C-- 14 CLUTCH
DAEWOO T-100 BL3
A103C027
9. AIign the shaft to the fork and instaII the boIt.
Tighten
Tighten the boIt to 35 N:m (26 Ib-ft).
A103C044
10. Coat the spIine on the cIutch disc with muIti-purpose
grease.
11. AIign the pressure pIate andthe cIutch disc ontothe
fIywheeI using the cIutch arbor J-42474.
12. InstaII the pressure pIate boIts.
Tighten
Tighten the boIts to 15 N:m (11 Ib-ft).
13. Remove the cIutch arbor J-42474.
14. InstaII the transaxIe into the vehicIe. Refer to Sec-
tion 5B, Five-Speed ManuaI TransaxIe.
15. InstaII the engine under covers. Refer toSection9N,
Frame and Underbody.
16. InstaII the Ieft front wheeI. Refer toSection 2E, Tires
and WheeIs.
17. Lower the vehicIe.
18. Connect the negative battery cabIe.
A103C010
CLUTCH PEDAL ADJUSTMENT
(HYDRAULIC)
Adjustment Procedure
1. Determine the cIutch pedaI pIay. Depress the cIutch
pedaI IightIy withyour handandmeasure the distance
when you feeI resistance.
CLUTCH 5C-- 15
DAEWOO T-100 BL3
A103C051
2. Adjust the cIutch pedaI pIay. Loosen the Iocknut and
turn the pushrod. CIutch pedaI pIay shouIdmeasure 6
to12 mm (0.2 to 0.5 inch). Tighten the Iocknut after
adjustment.
A103C038
3. Measure the cIutch pedaI traveI. Press the cIutch
pedaI aII the way to the fIoor. Measure from the start-
ing position to the ending position.
A103C039
4. Adjust the cIutch pedaI traveI. Loosen the Iocknut and
turn the boIt. CIutch pedaI traveI shouId measure
more than 130 mm (5.1 inches). Tighten the Iocknut
after adjustment.
5C-- 16 CLUTCH
DAEWOO T-100 BL3
A103C012
CLUTCH RELEASE POINT
ADJUSTMENT (HYDRAULIC)
Adjustment Procedure
1. AppIy the parking brake.
2. Run the engine at idIe speed.
3. WhiIe you move the shift Iever into the reverse posi-
tion, depress the cIutchpedaI sIowIy andmeasure the
distance between the point when gear noise is not
heardandthe point the cIutch pedaI is compIeteIy de-
pressed. The distance shouId be more than 30 mm
(1.2 inches).
4. If the distance is not more than 30 mm (1.2 inches),
check the foIIowing:
- CIutch pedaI height
- CIutch pedaI pIay
- Air in the system
- CIutch cover and disk
A103C013
AIR BLEEDING
BIeed the hydrauIic system to remove the air which en-
teredwhenthe pipes were disconnectedfor repairs. The
cIutch/brake fIuid in the cIutch/brake reservoir must be
maintainedat the MINIeveI or higher duringair bIeeding.
1. Attach a vinyI hose tothe bIeeder pIug. PIace the oth-
er end of the vinyI tube in a gIass container haIf-fiIIed
with brake fIuid.
2. SIowIy pump the cIutch pedaI severaI times.
3. WhiIe you press the cIutch pedaI, Ioosen the bIeeder
screwuntiI the fIuidstarts torun out. CIose the bIeed-
er screw.
4. Repeat Step 3 untiI there are no air bubbIes in the
fIuid.
5. FiII the reservoir with brake fIuid up to the MAX IeveI.
A103C046
CLUTCH MASTER CYLINDER
ASSEMBLY
RemovaI Procedure
Before disconnecting the reservoir tank hose, remove
the cIutch/brake fIuid from the reservoir tank.
1. Disconnect the spring cIamp on the master cyIinder.
Remove the reservoir hose.
CLUTCH 5C-- 17
DAEWOO T-100 BL3
A103C047
2. Disconnect the pipe connectedtothe master cyIinder.
A103C037
3. Remove the Iocking washer and the piston rod boIt
from the cIutch pedaI and piston rod cIevis.
A103C052
4. Remove the Iocknuts on the master cyIinder bracket.
Remove the master cyIinder in the directionof the en-
gine compartment.
5C-- 18 CLUTCH
DAEWOO T-100 BL3
A103C052
InstaIIation Procedure
1. InstaII the master cyIinder to the mounting boIts and
instaII the Iocknuts.
Tighten
Tighten the Iocknuts to 22 N:m (18 Ib-ft).
A103C047
2. Connect the pipe to the master cyIinder.
A103C046
3. Connect the reservoir hose tothe master cyIinder and
tighten the spring cIamp.
CLUTCH 5C-- 19
DAEWOO T-100 BL3
A103C037
4. Coat the piston rod boIt with muIti-purpose grease.
5. InstaII the piston rod cIevis, the piston rod boIt, and
the Iocking washer onto the cIutch pedaI.
6. BIeed the air. Refer to ''Air BIeeding'' in this section.
7. Adjust the cIutch pedaI. Refer to ''CIutch PedaI Ad-
justment'' in this section.
8. FiII the reservoir with cIutch/brake fIuid upto the MAX
IeveI.
A103C040
CLUTCH RELEASE CYLINDER
ASSEMBLY
RemovaI Procedure
1. Remove the boIt and disconnect the hose from the
cIutch reIease cyIinder.
A103C050
2. Remove the cIutch reIease cyIinder boIts andremove
the reIease cyIinder from the transaxIe.
5C-- 20 CLUTCH
DAEWOO T-100 BL3
A103C050
InstaIIation Procedure
1. Connect the reIease cyIinder to the transaxIe and
instaII the boIts.
Tighten
Tighten the reIease cyIinder boIts to60 N:m(44 Ib-ft).
A103C040
2. Connect the hose assembIy to the cyIinder body.
3. AppIy grease where the pushrod connects to the re-
Iease Iever. Be carefuI not to stain the boot.
4. BIeed the air. Refer to ''Air BIeeding'' in this section.
5. Adjust the cIutch pedaI. Refer to ''CIutch PedaI Ad-
justment (HydrauIic)'' in this section.
6. FiII the reservoir with cIutch/brake fIuid upto the MAX
IeveI.
A103C043
UNIT REPAIR
CLUTCH MASTER CYLINDER
DisassembIy Procedure
1. Remove the cIutch master cyIinder assembIy from
the vehicIe. Refer to "CIutch Master CyIinder Assem-
bIy" in this section.
2. Remove the boot and disconnect the piston stop ring
using ring pIiers.
CLUTCH 5C-- 21
DAEWOO T-100 BL3
A103C048
3. Remove the pushrod assembIy and the piston as-
sembIy.
4. Inspect the cIutch master cyIinder waII and the piston
for wear. RepIace the piston if necessary.
5. Inspect the cup and the piston for wear. FIuid Ieaks
wiII showwear on the cupandthe piston. RepIace the
cup and the piston if necessary.
6. Inspect the pushrod for wear. Repair the pushrod if
necessary.
A103C048
AssembIy Procedure
1. AppIy cIean fIuid to the piston assembIy cup and in-
sert the piston assembIy and the pushrod assembIy
into the master cyIinder body.
A103C043
2. InstaII the piston stop ring using ring pIiers. InstaII the
boot.
3. InstaII the cIutch master cyIinder assembIy into the
vehicIe. Refer to ''CIutch Master CyIinder AssembIy''
in this section.
5C-- 22 CLUTCH
DAEWOO T-100 BL3
A103C053
CLUTCH RELEASE CYLINDER
DisassembIy Procedure
1. Remove the cIutch reIease cyIinder assembIy from
the vehicIe. Refer to ''CIutch ReIease CyIinder As-
sembIy'' in this section.
2. Remove the boIts and brackets.
A103C041
3. Remove the boot and the pushrod.
A103C042
4. Compress the piston with a driver, then remove the
snap ring with snap ring pIiers.
5. Remove the piston assembIy.
CLUTCH 5C-- 23
DAEWOO T-100 BL3
A103C042
AssembIy Procedure
1. AppIy cIean cIutch fIuid to the piston and the cup.
2. InstaII the spring to the piston, and insert the assem-
bIy into the cyIinder body.
3. Compress the piston with a driver, then instaII the
snap ring with snap ring pIiers.
A103C041
4. InstaII the push rod and the boot.
A103C053
5. InstaII the brackets and the boIts.
6. InstaII the cIutch reIease cyIinder assembIy. Refer to
''CIutch ReIease CyIinder AssembIy'' in this section.
5C-- 24 CLUTCH
DAEWOO T-100 BL3
GENERAL DESCRIPTION
AND SYSTEMOPERATION
DRIVING MEMBERS
The driving members consist of two fIat surfaces ma-
chined to a smooth finish. One of these is the rear face
of the engine fIywheeI, and the other is the pressure
pIate. The pressure pIate is fitted into a steeI cover,
which is boIted to the fIywheeI.
DRIVEN MEMBERS
The driven member is the cIutch disc with a spIined hub
which is free to sIide Iengthwise aIong the spIines of the
input shaft, but which drives the input shaft through
these same spIines.
The driving and driven members are heId in contact by
spring pressure. This pressure is exerted by a dia-
phragm spring in the pressure pIate assembIy.
OPERATING MEMBERS
The cIutch reIease system consists of the cIutch pedaI,
the cIutch shaft, the fork, andthe reIease bearing. When
pressure is appIiedtothe cIutch pedaI, the fork pivots on
its shaft and the inner end pushes against the reIease
bearing. The bearing then pushes against the reIease
Ievers in the pressure pIate assembIy, thereby reIeasing
the cIutch.