Applies to: Hyundai Coupe/Tiburon 1998-2001
Clutch System Clutch Components
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[1.8L, 2.0L Pull type]
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  1. To remove the transaxle assembly first remove the air cleaner, joint, mounting bracket, and wiring etc.

  1. Remove the release lever.

    1. Loosen the release lever nut and washer.
    1. Remove the clevis pin and snap ring from the release cylinder.
    1. Remove the release lever.
      It is impossible to remove transaxle assembly without doing this step. Because clutch cover, release bearing and release fork are combined together.
  1. Loosen the bolts attached to the release cylinder and remove the release cylinder.

  1. Remove the transaxle assembly, after removing each bolt which connect the transaxle assembly and engine.

  1. In the state that the clutch cover is attached to the flywheel remove the release bearing using appropriate tool as shown.

    1. Rotate the release bearing in the easy direction in order to examine the snap ring.
    1. Insert the tool under the wave washer as shown in the illustration and locate in the center of snap ring.
    1. Widen the space of snap ring by pushing the bearing as shown in the illustration.
    1. The snap ring-widen state is like as shown the figure.
    1. In the snap ring-widen state pull out the release bearing and remove it.
  1. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.

  1. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

    Do not clean the clutch disc or release bearing with cleaning solvent.
  1. Remove the release fork shaft and bushing.

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  1. Clean the dust on the clutch housing using the vacuum brush or dry floor cloth and ought not to use the compressed air absolutely.

    Check the oil leakage in engine rear bearing oil seal and transaxle front oil seal. If leaky, repair them.

  1. The friction surface of pressure plate must be equalized to entire disc surface.

    If any part is excessive wear at the point of contact, the pressure plate is installed badly.

  1. Check the friction surface of flywheel for color change, partial damage, small crack and wear.

  1. Don't touch the clutch disc with the contaminated hands or gloves.

    Replace the clutch disc, if the facing is stained with oil or grease. Measure the rivet sink and replace the clutch disc, if it is less than 3mm.

    Clutch disc 0.3 mm ( 0.012 in )
  1. Check the hub spline and torsion spring of clutch disc for excessive wear.

  1. Clean the friction surface of pressure plate with cleaning solvent.

  1. Measure the flat of pressure plate with a square. If it exceeds 0.5mm, replace it.

    Check the pressure plate surface for wear, cracks and color change.

  1. Check that the three-dowel on the flywheel is installed completely.

The release bearing is packed with grease. Do not use cleaning solvent or oil.
  1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.

  1. Replace the bearing if the release fork contacting points are worn abnormally.


If there is abnormal wear at the point of contact with the bearing, replace the release fork.

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  1. Apply multipurpose grease to the spline of disc.

    Grease: MOLYWHITE TA No.2

    When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; it can cause clutch slippage and judder.
  1. Install the clutch disc assembly to the flywheel using special tool (09411-11000).

  1. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.

    Clutch cover bolt 15-22 Nm ( 150-220 kg·cm, 11-16 lb·ft )
  1. Align the bearing to the release fork and then install it to the sleeve of housing.

    Apply multipurpose grease (MOLYWHITE TA No.2) to the grease groove of bearing sleeve and contact point of release fork.
  1. Install the release lever to the release fork.

    If transaxle assembly is installed to engine without doing this step, release bearing can be separated according as the release fork rotates free.
  1. Install the transaxle assembly to the engine.

  1. After finishing step 6, pushing the release lever to the arrow mark it is sounded click that the release bearing and clutch cover are aligned correctly.

    Release lever operating range: 3° or less

    If the range is over 3° it is a symptom that the release bearing and clutch cover are not aligned correctly. So, push the release lever to the arrow mark one more time.