Clutch Replace
(Figure 1) Clutch Assembly and Pilot Bearing:
Removing the Pilot Bearing:
Pilot Bearing Driver:
(Figure 4.) Release Bearing:
TOOLS REQUIRED (or equivalents)
^ J-5824-01, Clutch alignment tool.
^ J-1448, Pilot bearing puller.
^ J-1522, Pilot bearing driver.
WARNING: When servicing clutch parts, do not create dust by grinding or sanding clutch disc or by cleaning parts with a dry brush or with compressed air. (A water dampened cloth (NOT SOAKED) should be used.) The clutch disc contains asbestos fibers which can become air-borne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.
REMOVAL
1. Remove transmission, refer to Transmission / Service and Repair.
2. Adjusting rod or the secondary (slave) cylinder.
3. Remove inspection cover Screws and the cover.
4. Remove the flywheel housing bolts and then the housing.
5. Remove clutch fork boot, clutch fork and the release bearing.
^ Pry the clutch fork off the ball stud.
^ Pry the retainer out of the clutch fork if it is worn or damaged.
6. Remove the ball stud.
7. Remove the cover assembly screws and the spring washers (205/206 in figure 1).
NOTES:
^ Install J-5824-01 or a used clutch drive gear to support the clutch.
^ Mark the flywheel, clutch cover and a pressure plate lug for alignment when installing.
^ Loosen each screw one turn at a time to avoid warping the clutch cover.
8. Remove the cover assembly and the driven plate (disc) and the J-5824-01 clutch alignment tool.
9. Use J-1448 to remove pilot bearing if it is worn or damaged.
10. Remove the pressure plate screws and straps (218/219 in figure 1) and note the location of the retracting springs.
11. Remove the pressure plate.
Clean
^ All parts with a clean, water dampened cloth to remove any asbestos fibers.
^ Clutch fork, the flywheel housing and the ball stud with solvent. Wipe dry.
NOTE: The release bearing is permanently packed with lubricant and should NOT be soaked in cleaning solvent as this will dissolve the lubricant.
Inspection
^ Inspect all parts for wear and damage.
^ Inspect contact surfaces for scoring, and flatness with a straight edge. Driven plate run-out must not be more than 5.08 mm (0.20 in).
^ Inspect friction pads for scoring, gouges, and loose rivets. Check to see if they are oil soaked.
^ Inspect all splines for nicks, burrs and sliding fit.
^ Inspect all springs for bending and breaks.
^ Inspect boot for tears and brittleness.
Measurement
^ Measure the transmission pilot hole in the clutch housing for run out using a dial indicator. Run out should not be more than 0.380 mm (0.015 in).
INSTALLATION
1. Install the pressure plate, (make sure to line up the marks made during removal), with the straps and screws (218/219).
^ Install the retracting springs in the positions from which they were removed.
2. Install a new pilot bearing if needed. Use J-1522 as needed to drive the bearing in until the tool bottoms out.
^ Lubricate the bearing with a few drops of machine oil.
3. Driven plate (disc) and cover assembly.
NOTES:
^ Install J-5824-01 or a used clutch drive gear to support the clutch.
^ Align the marks made during removal.
4. Install new spring washers and bolts (205/206) then remove the clutch alignment tool.
CAUTION:
^ Tighten each screw one turn at a time to avoid warping the clutch cover.
^ Be careful not to use too much lubricant. Excessive lubricant may get on clutch fingers and cause slippage or damage to the clutch.
5. Install the ball stud. Coat the rounded end and pack the seat with high temperature grease.
6. Install a new retainer if needed.
NOTE: The retainer must be installed so the fingers and tabs fit into the release bearing groove and the retainer wraps around the flat side of the ball stud head.
7. Pack the inside recess and the outside groove of the release bearing with high temperature grease as shown (figure 4), then install the bearing, clutch fork and the boot.
8. Install the flywheel housing and bolts.
9. Install the inspection cover and screws.
10. Install the adjusting rod or secondary (slave) cylinder.
11. Install the retaining and pull back springs (if used).
12. Install the transmission, refer to Transmission / Service and Repair.
13. Adjust the clutch linkage as needed.