Clutch: Service and Repair

The hydraulic clutch system uses a constant running throwout bearing which rides against the diaphragm fingers on the pressure plate. After a period of time, the ball stud in which the fork pivots will become dry from lack of lubrication and cause noisy operation. To repair this condition it will be necessary to replace the clutch plate, ball stud, clutch fork and disc.

1. Remove clutch slave cylinder.
2. Remove inspection cover bolts, then the cover.
3. Remove transmission.
4. Remove clutch housing bolts, then the housing.
5. Remove clutch fork and release bearing, prying clutch fork off ball stud.
6. Install clutch alignment tool No. J33169, or equivalent, or used clutch drive gear to support clutch.
7. Mark flywheel, clutch cover and pressure plate lug for alignment during installation.
8. Remove clutch cover bolts, washers, then the clutch cover assembly and clutch plate.
9. Remove clutch alignment tool, then the pilot bearing, if it is worn or damaged, using clutch pilot bearing remover tool No. J-23907, or equivalent.
10. Reverse procedure to install, noting the following:
a. Install new pilot bearing as necessary, using driver handle tool No. J-8092, or equivalent, with clutch pilot bearing installer tool No. J-26516-A, or equivalent, to drive bearing in until tool bottoms out. Lubricate bearing with few drops of machine oil.
b. Tighten flywheel bolts to specifications, each screw one turn at a time to avoid warping clutch cover.
c. When installing clutch fork, seat and new retainer, pack seat and coat rounded end of ball stud with high temperature (wheel bearing) grease.
d. Tighten clutch housing to engine bolts to specifications.
e. Tighten transmission inspection cover bolts to specifications.