Kia Forte: Clutch System

Kia Forte 2019-2025 (BD) Service Manual / Clutch System

Service data

Service Data

Items		Specifications
Clutch operation method		Hydraulic type
Clutch cover	Type	Diaphragm spring strap
Clutch disc	Type	Single dry with diaphragm
	Facing diameter (Outer × inner)	Ø235 × Ø155 mm (Ø9.2520 × Ø6.1024 in.)
	Thickness [When free]	Ø8.3 ± Ø0.3 (0.3268 ± 0.0118 in.)
	Rivet depth	Min 1.1 mm (0.0433 in.)

Service Standard

Item	Specification
Clutch disc rivet depth	0.3 mm (0.0118 in.)

Tightening torque

Tightening Torques

Item	N·m	kgf·m	lb·ft
Clutch pedal mounting bolt & nut	16.7 - 25.5	1.7 - 2.6	12.3 - 18.8
Clutch release cylinder mounting bolt	14.7 - 21.6	1.5 - 2.2	10.8 - 15.9
Concentric slave cylinder assembly mounting bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Ignition lock & clutch switch mounting bolt	2.0 - 5.9	0.2 - 0.6	1.4 - 4.3
Clutch tube bracket mounting bolt	7.8 - 9.8	0.8 - 1.0	5.8 - 7.2
Clutch release cylinder bleed plug	7.8 - 13.7	0.8 - 1.4	5.8 - 10.1
Clutch release cylinder assembly mounting nut	14.7 - 21.6	1.5 - 2.2	10.8 - 15.9
Concentric slave cylinder assembly mounting bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Clutch cover mounting bolt (Gasoline 1.6)	24.5 - 35.3	2.5 - 3.6	18.1 - 26.0
Clutch cover mounting bolt (Gasoline 2.0)	11.8 - 14.7	1.2 - 1.5	8.7 - 10.8

Lubricant

Lubricants

Items	Specified lubricants	Quantity
Clutch release cylinder assembly	Brake fluid DOT 3 or DOT 4	As required
Clutch pedal shaft and bushings	Chassis grease SAE J310a, NLGI No.1	0.2 - 2.0 g
Input shaft spline	CASMOLY L9508	0.2 g
Release bearing & Fork		0.3 - 0.5 g
Release Fork & Fulcrum		0.5 - 1.0 g
Release Cylinder & Fork		0.4 - 0.8 g
Clutch Release Bearing & Clutch Housing		0.5 - 1.0 g

Special service tools

Special Service Tools

Tool Name / Number	Illustration	Description
Clutch disc guide 09411-1P000		Installation of the clutch disc.

Troubleshooting

Trouble symptom

Suspect area

Remedy

Clutch slipping

•	Car will not respond to engine speed during acceleration

•	Insufficient vehicle speed

•	Lack of power during uphill driving

Insufficient pedal free play

Adjust

Clogged hydraulic system

Correct or replace parts

Excessive wear of clutch disc facing

Replace

Hardened clutch disc facing, or oil on surface

Replace

Damaged pressure plate or flywheel

Replace

Weak or broken pressure spring

Replace

Difficult gear shifting (gear noise during shifting)

Excessive pedal free play

Adjust

Hydraulic system fluid leaks, air trapping or clogging

Repair or replace parts

Unusual wear or corrosion of the clutch disc spline

Replace

Excessive vibration (distortion) of the clutch disc

Replace

Clutch noisy

When the clutch is not used

Insufficient play of the clutch pedal

Adjust

Excessive wear of the clutch disc facing

Replace

A noise is heard after the clutch is disengaged

Unusual wear and/ or damage of the release bearing

Replace

A noise is heard when the clutch is disengaged

Insufficient grease on the sliding surface of the bearing sleeve

Repair

Improperly installed clutch assembly or bearing

Repair

A noise is heard when the car suddenly rolled up with the clutch partially engaged

Damaged pilot bushing

Replace

Hard pedal effort

Insufficient lubrication of the clutch pedal

Repair

Insufficient lubrication of the spline part of clutch disc

Repair

Insufficient lubrication of the clutch release lever shaft

Repair

Hard to shift or will not shift

Excessive clutch pedal free play

Adjust the pedal free play

Faulty of the clutch release cylinder

Repair the release cylinder

Clutch disc out of place, runout is excessive or lining broken

Inspect the clutch disc

Spline on the input shaft or clutch disc dirty or burned

Repair as necessary

Faulty of the clutch pressure plate

Replace the clutch cover

Clutch slips

Insufficient clutch pedal free play

Adjust the pedal free play

Clogged of the hydraulic system

Repair or replace parts

Clutch disc lining oily or worn out

Inspect the clutch disc

Faulty pressure plate

Replace the clutch cover

Binding of the release fork

Inspect the release fork

Clutch grabs/chatters

Clutch disc lining oily or worn out

Inspect the clutch disc

Faulty the pressure plate

Replace the clutch cover

Bent clutch diaphragm spring

Replace the clutch cover

Worn or broken torsion spring

Replace the clutch disc

Engine mounts loose

Repair as necessary

Clutch noisy

Damaged the clutch pedal bushing

Replace the clutch pedal bushing

Loose part inside housing

Repair as necessary

Worn or dirty release bearing

Replace the replease bearing

Sticking release fork or linkage

Repair as necessary

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