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

Kia Rio 2017-2025 YB Service Manual / Clutch System / Clutch Release Fork and Clutch Release Bearing

Components and components location

Components

1. Clutch release fork
2. Clutch cover assembly

3. Clutch disk assembly
4. Clutch release bearing

[Gasoline 1.2 only]

1. Clutch disc
2. Clutch cover
3. Clutch release bearing

4. Clutch release lever assembly
5. Cltuch release fork
6. Return clip

Repair procedures

Removal

[Gasoline 1.2]

1.	Remove the transaxle assembly. G 1.2 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

2.	Remove the reamer bolt (A).

3.	Remove the return clip (A).

4.	Remove the clutch release fork.

[Gasoline 1.0 T-GDI, 1.4, Diesel 1.4]

1.	Remove the transaxle assembly. D 1.4 U2 TCI (Refer to Manual Transaxle System - "Manual Transaxle") G 1.0 T-GDI (Refer to Manual Transaxle System - "Manual Transaxle") G 1.4 MPI (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).

Inspection

1.	Check for damage to boot.

2.	Check for deformation to clutch release fork.

3.	Check for deformation to clutch release bearing.

Installation

1.	Install the boot (A).

2.	Install the clip to the clutch release fork.

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

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. D 1.4 U2 TCI (Refer to Manual Transaxle System - "Manual Transaxle") G 1.0 T-GDI (Refer to Manual Transaxle System - "Manual Transaxle") G 1.4 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

[Gasoline 1.2]

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.

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 (A).

Apply multi purpose grease to on contact surface of release cylinder and 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.

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 1.2 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

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