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Ask Roadside Jerry Your Own Question

Roadside Jerry
Roadside Jerry, Auto Mechanic
Category: Car
Satisfied Customers: 2948
Experience:  Auto Mehanic 39 years,30 with the NYPD Fleet Service Division
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how do i change the clutch in a 2004 tiburon

Customer Question

how do i change the clutch in a 2004 tiburon
Submitted: 5 years ago.
Category: Car
Expert:  Roadside Jerry replied 5 years ago.

Hi, You first need to remove the transaxle,then you can replace the clutch,here are the instructions from the service manual for doing the repair.First are instructioms for the transaxle R andR, then the clutch.The tool for lining up the clutch disc should should be included with the clutch replacement kit,or you can purchase an inexpensive one at the auto supply store,it is needed.

 

  • Remove or disconnect the following:
    • Engine cover
    • Battery terminal
    • Air duct
    • Battery tray
    • Upper and lower air cleaner

       

    • Back-up lamp switch
    • Crankshaft Position Sensor, O2 Sensor, Oil Pressure Switch wiring bracket and the connectors
    • Brake fluid leveling sensor connector
    • Speedometer driven gear connector
    • Clutch release cylinder mounting bolt
    • Shift and select cable cotter pins (transaxle side)
    • Shift and select cable clips (transaxle side)
    • Steering column shaft joint
    • Power steering oil pump hose
    • Clip of the power steering return hose and disconnect the hose
    • Upper connecting transaxle bolt
    • Starter motor
  • Install the engine support fixture.
  • Remove or disconnect the following:
    • Tire and caliper
    • Transaxle side cover and under cover

       

    • Tie rod end
    • Wheel speed sensor and the knuckle mounting bolt
  • Drain the oil.
  • Remove or disconnect the following:
    • Transaxle mounting bracket
    • Front roll stopper
    • Rear roll stopper
    • Drive shaft

       

    • Front muffler
    • Sub frame mounting bolt
  • Install the transaxle jack.
  • Remove or disconnect the following:
    • Transaxle lower mounting bolt to the engine
    • Transaxle assembly
  • To Install:

    Tightening Torque

     

    1. Install or connect the following:
      • Transaxle assembly
      • Transaxle lower mounting bolt to the engine
    2. Remove the transaxle jack.
    3. Install or connect the following:
      • Sub frame mounting bolt
      • Front muffler
      • Drive shaft
      • Rear roll stopper
      • Front roll stopper
      • Transaxle mounting bracket
      • Wheel speed sensor and the knuckle mounting bolt
      • Tie rod end
      • Transaxle side cover and under cover
      • Tire and caliper
      • Starter motor
      • Upper connecting transaxle bolt
      • Clip of the power steering return hose and connect the hose
      • Power steering oil pump hose
      • Steering column shaft joint
      • Shift and select cable clips (transaxle side)
      • Shift and select cable cotter pins (transaxle side)
      • Clutch release cylinder mounting bolt
      • Speedometer driven gear connector
      • Brake fluid leveling sensor connector
      • Crankshaft Position Sensor, O2 Sensor, Oil Pressure Switch connectors and bracket
      • Back-up lamp switch
      • Upper and lower air cleaner
      • Battery tray
      • Air duct
      • Battery terminal
      • Engine cover
      • Clutch Disc & Pressure Plate

        Removal & Installation

        To Remove:

        Clutch Cover and Disc

         

        1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
        2. Remove or disconnect the following:
          • Clutch fluid
          • Transaxle oil
          • Transaxle assembly

           

        3. Insert special tool (09411-25000) into the disc.
        4. Disconnect clutch cover bolts in a star pattern.

        CAUTION
        Avoid bending the cover flange by loosening the bolts 1 to 2 turns at a time in succession. Do not clean the clutch disc or release bearing with solvent.

        To Install:

         

         

         

        1. Apply multipurpose grease to the release bearing contact surfaces, and the contact surface of the clutch release fork, the groove of the release bearing, and the contact surface of the clutch release lever fulcrum.
        2. Remove any oil or grease from the flywheel and pressure plate.
        3. Apply multipurpose grease to the clutch disc splines and input shaft splines.
        4. Install or connect the following:
          • Clutch disc to flywheel with special tool (09411-25000)

            NOTE: Make sure that the manufacturer's stamp is towards the pressure plate side.

          • Clutch cover assembly onto flywheel and tighten the bolts diagonally
            1. Torque to: 11 - 15 ft. lbs. (15 - 22 Nm)
        5. Remove special tool.

           

        6. Install transaxle and adjust the pedal.
        7. Fill transaxle oil and clutch fluid.

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