Kia 4110024520 Disc Assembly-Clutch

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Access to clutch components typically requires removing the transaxle from the vehicle, and if the engine is being overhauled, it's advisable to check and replace worn clutch components due to their low cost compared to the effort involved in accessing them. Begin by removing the transaxle while supporting the engine, preferably with an engine hoist, and ensure a piece of wood is used to protect the oil pan if a jack is employed. The clutch fork can remain attached to the bellhousing. For models from 2001 to 2006, turn the release bearing to view the snap-ring, use snap-ring pliers to engage it, and then remove the release bearing. For all models, inspect the flywheel and clutch for indexing marks, marking them if necessary for proper alignment during installation. Use a clutch alignment tool to support the disc, then loosen the pressure plate bolts in a criss-cross pattern before removing the pressure plate and clutch disc. During inspection, check the flywheel for cracks and defects, and if imperfections are minor, a machine shop can smooth the surface. Inspect the clutch disc lining for sufficient thickness and any damage, replacing it if necessary, along with the pressure plate and release bearing. Clean the flywheel and pressure plate surfaces thoroughly before positioning the disc correctly, securing it with the alignment tool, and then placing the pressure plate in position while aligning any marks made earlier. Tighten the bolts in a criss-cross pattern to avoid distortion, and complete the installation by reversing the removal steps.

To remove the clutch, the transaxle must be detached. Use a clutch alignment tool to support the clutch disc during removal and loosen the pressure plate-to-flywheel bolts in a criss-cross pattern. Check the flywheel and pressure plate for indexing marks and replace the bearings. Clean the machined surfaces with brake cleaner or acetone and install the new pilot bearing. Position the clutch disc and pressure plate against the flywheel, center the clutch disc, and tighten the bolts. Lubricate the release bearing and install it. Finally, reinstall the transaxle and other components.