Kia Forte: Clutch System

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

Service data
Service Data

Items
Specifications
Clutch operation method
Hydraulic type
Clutch cover 
 Type
Diaphragm spring strap
Clutch disc
 Type
Single dry with diaphragm
Facing diameter
(Outer × inner)
Ø235 × Ø155 mm (Ø9.2520 × Ø6.1024 in.)
Thickness [When free]
Ø8.3 ± Ø0.3 (0.3268 ± 0.0118 in.)
Rivet depth
Min 1.1 mm (0.0433 in.)

Service Standard

Item
Specification
Clutch disc rivet depth
0.3 mm (0.0118 in.)

Tightening torque
Tightening Torques

Item
N·m
kgf·m
lb·ft
Clutch pedal mounting bolt & nut
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Clutch release cylinder mounting bolt
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9
Concentric slave cylinder assembly mounting bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5
Ignition lock & clutch switch mounting bolt
2.0 - 5.9
0.2 - 0.6
1.4 - 4.3
Clutch tube bracket mounting bolt
7.8 - 9.8
0.8 - 1.0
5.8 - 7.2
Clutch release cylinder bleed plug
7.8 - 13.7
0.8 - 1.4
5.8 - 10.1
Clutch release cylinder assembly mounting nut
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9
Concentric slave cylinder assembly mounting bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5
Clutch cover mounting bolt (Gasoline 1.6)
24.5 - 35.3
2.5 - 3.6
18.1 - 26.0
Clutch cover mounting bolt (Gasoline 2.0)
11.8 - 14.7
1.2 - 1.5
8.7 - 10.8

Lubricant
Lubricants

Items
 Specified lubricants
 Quantity
Clutch release cylinder assembly
Brake fluid DOT 3 or DOT 4
 As required
Clutch pedal shaft and bushings
Chassis grease SAE J310a, NLGI No.1
0.2 - 2.0 g
Input shaft spline
CASMOLY L9508
0.2 g
Release bearing & Fork
0.3 - 0.5 g
Release Fork & Fulcrum
0.5 - 1.0 g
Release Cylinder & Fork
0.4 - 0.8 g
Clutch Release Bearing & Clutch Housing
0.5 - 1.0 g

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Clutch disc guide
09411-1P000

Installation of the clutch disc.

Troubleshooting
Troubleshooting

Trouble symptom
Suspect area
Remedy 
Clutch slipping

Car will not respond to engine speed during acceleration

Insufficient vehicle speed

Lack of power during uphill driving 

Insufficient pedal free play
Adjust
Clogged hydraulic system
Correct or replace parts
Excessive wear of clutch disc facing
Replace
Hardened clutch disc facing, or oil on surface
Replace
Damaged pressure plate or flywheel
Replace
Weak or broken pressure spring
Replace
Difficult gear shifting (gear noise during shifting)
Excessive pedal free play
Adjust
Hydraulic system fluid leaks, air trapping or clogging
Repair or replace parts
Unusual wear or corrosion of the clutch disc spline
Replace
Excessive vibration (distortion) of the clutch disc
Replace
Clutch noisy
When the clutch is not used
Insufficient play of the clutch pedal
Adjust
Excessive wear of the clutch disc facing
Replace
A noise is heard after the clutch is disengaged
Unusual wear and/ or damage of the release bearing
Replace
A noise is heard when the clutch is disengaged
Insufficient grease on the sliding surface of the bearing sleeve
Repair
Improperly installed clutch assembly or bearing
Repair
A noise is heard when the car suddenly rolled up with the clutch partially engaged
Damaged pilot bushing
Replace
Hard pedal effort
Insufficient lubrication of the clutch pedal
Repair
Insufficient lubrication of the spline part of clutch disc
Repair
Insufficient lubrication of the clutch release lever shaft
Repair
Hard to shift or will not shift
Excessive clutch pedal free play
Adjust the pedal free play
Faulty of the clutch release cylinder
Repair the release cylinder
Clutch disc out of place, runout is excessive or lining broken
Inspect the clutch disc
Spline on the input shaft or clutch disc dirty or burned
Repair as necessary
Faulty of the clutch pressure plate
Replace the clutch cover
Clutch slips
Insufficient clutch pedal free play
Adjust the pedal free play
Clogged of the hydraulic system
Repair or replace parts
Clutch disc lining oily or worn out
Inspect the clutch disc
Faulty pressure plate
Replace the clutch cover
Binding of the release fork
Inspect the release fork
Clutch grabs/chatters
Clutch disc lining oily or worn out
Inspect the clutch disc
Faulty the pressure plate
Replace the clutch cover
Bent clutch diaphragm spring
Replace the clutch cover
Worn or broken torsion spring
Replace the clutch disc
Engine mounts loose
Repair as necessary
Clutch noisy
Damaged the clutch pedal bushing
Replace the clutch pedal bushing
Loose part inside housing
Repair as necessary
Worn or dirty release bearing
Replace the replease bearing
Sticking release fork or linkage
Repair as necessary

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