Clutch Assembly Service

Remove
1. Remove gearbox assembly.





2. Release push rod gaiter from clutch lever.
3. Remove 2 bolts securing clutch slave cylinder. Tie cylinder aside.





4. Remove 9 bolts securing flywheel access cover to clutch housing. Remove cover.





5. Remove 8 bolts securing clutch housing. Disengage release lever from release bearing. Remove clutch housing.
6. If clutch cover is to be refitted, mark cover and flywheel to aid re-assembly.
7. Restrain flywheel.





8. Working diagonally, sequentially slacken 6 bolts securing clutch cover to flywheel. Remove bolts.





9. Remove cover assembly. Collect friction plate.

Check

10. Check linings of friction plate for excessive or uneven wear, burning or contamination.
11. Check splines of friction plate for excessive wear.
12. Check friction surface of cover for burning distortion or scoring.
13. Check fingers of cover for cracks and distortion.
14. Check release bearing for smooth operation.
15. Renew components as necessary.

CAUTION: Bearing is packed with grease, do not wash in solvent.

Refit

16. Ensure mating faces are clean.

NOTE: New friction plates are supplied with splines pre-greased.

17. If refitting existing friction plate, smear splines with 'Molykote FB180'.





18. Position friction plate on flywheel. Fit LRT-12-001 to align plate.
19. Position cover. Locate on dowels.

NOTE: If original cover is refitted, align marks.

20. Secure cover with bolts. Tighten progressively, in a diagonal sequence to 40 Nm (30 ft. lbs.). Remove LRT-12-001.
21. Position clutch housing onto dowels. Ensure release fork engages with release bearing.
22. Secure clutch housing with bolts. Tighten to 40 Nm (30 ft. lbs.)
23. Position flywheel access cover. Secure with bolts.
24. Smear release lever push rod socket with 'Molykote FB180'.
25. Position slave cylinder on clutch housing. Ensure pushrod is engaged with lever. Secure cylinder with bolts. Tighten to 45 Nm (33 ft. lbs.)
26. Secure push rod gaiter to clutch lever.
27. Fit gearbox assembly.