This is part 3 of our project "How to replace the clutch in a 2002 Hyundai Accent GS", if you landed in this page while searching the web, and would like to see this job from the start click here.

If you would like to learn more about how the clutch system works, visit our page Clutch

  

   


   

   

   



   

   

   

    

  

                  Prev page.
   
 

.

.

.

 

 

Remove the bolts that secure the clutch pressure plate to the flywheel, it will be easier if you leave two bolts opposite from each other finger-tight while you remove the rest of the bolts, hold the pressure plate with one hand as you remove the remaining two bolts, make sure that you catch the clutch disc as it slides down when you pull the pressure plate away from the flywheel. 











With the clutch assembly removed, proceed to remove the flywheel by removing the 5 bolts that secure it to the crankshaft, hold the flywheel with a pry-bar as shown in the picture while you loosen the bolts with a 12 point socket and a braker bar.

It is necesary to have the flywheel machined to make sure that the new clutch disc will have a flat surface to engage to, specially if the clutch disc in your car was worn-out and made grooves to the flywheel, the machine shop will determine if the flywheel is still reusable, in worst case scenario, you may have to buy a new flywheel .










Next, clean clutch fork and transmission output shaft with a towel and brake cleaner, apply a light coat of grease to the tips of the clutch fork that make contact with the clutch release bearing, apply a very light coat of grease to the transmission output shaft splines and the surface where the clutch release bearing slides in and out. 













Install the new clutch release bearing.

 

 

 

 

 

 
Next, install the flywheel, torque the flywheel bolts in three steps, start by tightening the bolts to 20 Ft-lbs start with one bolt, moving to the bolt located in the opposite side followed by the one located 90 degrees from the one you just tightened and so forth, 2nd step, tightem them in similar sequence but tighten them to 50 Ft-lbs this time, tighten them one last time to the manufacturer specifications.

  
















Clean surface where the new clutch will make contact on the pressure plate and flywheel using brake cleaner.







To install the clutch disc and pressure plate, you will need to use a clutch alignment tool similar to the one shown in the picture to align the clutch disc. ( you can see it in the center of the pressure plate )

Most new clutch sets come with a plastic clutch alignment tool included, if yours didn't come with one, you can buy these inexpensive tools at your local part store for about $5.00.

In order not to damage the new pressura plate, tighten all the bolts in several steps evenly, once all the bolts are bolted all the way , torque them to the manufacturer specifications.

Install the transaxle back in place, install the flywheel bolts, install the lower transmission monts followed by the upper transmission mount with their respective brackets. 





.

.

Apply a light coat of grease to the output shaft seals before you install the driveaxles.

















Apply a light coat of antiseze to the drive axle splines, install the axles on both sides, make sure that you don't forget to tighten the lower ball joints and new cotter pins are installed in the drive axle retaining nuts.

Install the remaining components in the reverse order they were removed, if the transmission oil you drained from the transaxle was clean, you can add the same oil back to the transaxle, otherwise, this is the perfect opportunity to add new oil to the transaxle.

 

 

 

 

 

  

  Once you are done installing all the parts back on the vehicle, install the front wheels, lower the car to the ground, check the clutch fluid level, start the car to make sure that no unusual noises are present, take the vehicle for a test drive, if you did everything correctly, the clutch should operate smoothly, when you come back from test driving the car, open the hood again, look for any leaks coming from the clutch slave cylinder and the axle seals, there shouldn't be any fluid leaks.


Prev page.