Kia Forte: Clutch System / Clutch Cover And Disc

Kia Forte 2019-2020 (BD) Service Manual / Clutch System / Clutch Cover And Disc

Components and components location
Components
[Gasoline 1.6 / Diesel 1.6 / Gasoline 1.6 T-GDI]

1. Manual transaxle assembly
2. Clutch cover assembly
3. Clutch disc assembly

[Gasoline 2.0]

1. Manual transaxle assembly
2. Clutch release fork
3. Clutch cover assembly
4. Clutch disk assembly
5. Clutch release bearing

Repair procedures
Removal
1.

Remove the manual transaxle assembly.

G 1.6 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

G 2.0 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

D 1.6 TCI-NEW-U (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.6 T-GDI GAMMA (Refer to Manual Transaxle System - "Manual Transaxle")

2.

Remove the clutch cover assembly after loosening the bolts.

  

Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions.

[Gasoline 1.6]

[Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI]

Inspection
1.

Inspect diaphragm spring wear which is in contact with clutch release bearing.

2.

Check the clutch cover and disc surface for wear or cracks.

3.

Check the clutch disc facing for slipping or oil marks.

4.

Measure the depth from the clutch lining surface to rivet. If the measured value is less than the specification below, replace it.

Standard value

Clutch disc thickness (A)[when free] : 8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)

Clutch disc rivet depth (B) : 1.1 mm (0.0433 in.)

Installation
  

If reinstalling used cover, the cover should be installed with its clutch disc as a set.

1.

Apply grease on a disc spline part and transaxle input shaft spline part as required.

Specified grease: CASMOLY L9508

Amount: 0.1 - 0.3 g

  

When not applying: Excessive wear of splines and bad clutch operation can occur.

When applying excessively: Grease can be spread by the centrifugal force which can contaminate the clutch disc. This can cause a loss of friction force causing a slip.

2.

Install the clutch disc and the cover with special tool (09411-1P000).

  

Possible problems when the disc is installed in the opposite direction.

Transaxle shift error or a strangesound can occur due to clutch separation.

Gasoline 1.6 : The 'T/M SIDE' marked surface should face the transaxle.

Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI : The 'FLYWHELL SIDE' marked surface should face the flywheel.

3.

Install the clutch cover bolts.

Tightening torque

Gasoline 1.6 : 24.5 - 35.3 N·m (2.5 - 3.6 kgf·m, 18.1 - 26.0 lb·ft)

Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI : 11.8 - 14.7 N·m (1.2 - 1.5 kgf·m, , 8.7 - 10.8 lb·ft)

  

Install the all the components with the specified torques. If not, the clutch torque transaxle may have concerns or the mounting bolt can loosen.

When installing the clutch cover assembly, check the fastening order for each number of bolts and tighten the bolts loosely. Then, faste the bolts to their proper tightening torque. This can prevent twisting and vibration of the cover, and lifting of the pressure plate.

Fastening order for each number (6 or 9) of bolts for installing the clutch cover assembly

4.

Remove the clutch disc guide special tool (09411-1P000).

5.

Install the transaxle assembly.

G 1.6 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

G 2.0 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

D 1.6 TCI-NEW-U (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.6 T-GDI GAMMA (Refer to Manual Transaxle System - "Manual Transaxle")

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