Kia Picanto: Clutch System / Clutch Release Fork and Clutch Release Bearing

Kia Picanto JA 2017-2021 Service & Repair Manual / Clutch System / Clutch System / Clutch Release Fork and Clutch Release Bearing

Components and components location
Components
[Kappa 1.0 MPI / FFV, Kappa 1.2 MPI]

1. Clutch disc assembly
2. Clutch cover assembly
3. Clutch release bearing
4. Clutch release lever assembly
5. Return spring
6. Clutch release fork
7. Return clip

[Kappa 1.0 T-GDI]

1. Clutch release fork
2. Clutch cover assembly
3. Clutch disk assembly
4. Clutch release bearing

Repair procedures
Removal
[Kappa 1.0 MPI / FFV, Kappa 1.2 MPI]
1.
Remove the transaxle assembly.
G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.2 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")
2.
Remove the reamer bolt.

3.
Remove the return clip (A) from the release bearing and then remove the release fork and release bearing.

[Kappa 1.0 T-GDI]
1.
Remove the transaxle assembly.
G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
2.
Remove the clutch release bearing (A).

3.
Pull the clip (A).

4.
Remove the clutch release fork (A).

5.
Remove the boot (A).

Installation
[Kappa 1.0 MPI / FFV, Kappa 1.2 MPI]
1.
Apply multi purpose grease to release fork assembly.
   
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; it can cause clutch slippage and judder.
2.
Apply multi purpose grease into the groove of the release bearing.
Grease : CASMOLY L9508 (0.4 - 0.8g)

3.
Install the release bearing and release fork to clutch housing.

4.
Install the reamer bolt.

5.
Apply multi purpose grease to on contact surface of lever (A).
Grease : CASMOLY L9508 (0.2 - 0.4g)

6.
Clean the surfaces of the flywheel and pressure plate throughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
7.
Apply a small amount of multi purpose grease to the input shaft splines (A).
Grease : CASMOLY L9508 (approx. 0.2g)

   
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
8.
Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
9.
Install the transaxle assembly.
G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.2 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")
[Kappa 1.0 T-GDI]
1.
Install the boot (A).

2.
Install the clip to the clutch release fork.
3.
Apply to grease in location A, B and C.
Location
Quantity (g)
Remarks
A
0.3 - 0.5
Release bearing & Fork
B
0.5 - 1.0
Release Fork & Fulcrum
C
0.4 - 0.8
Release cylinder & Fork

4.
Apply the grease to the hole surface of the clutch release bearing all around.
Specified grease: CASMOLY L9508
Amount: 0.5 - 1.0 g

5.
Install the clutch release fork (B), clutch release bearing (A).

6.
Install the transaxle assembly.
G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
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