REMOVAL & INSTALLATION

CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer-causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface. When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Transmission

   WARNING
   Removing the bolts on one side of the pressure plate will warp the pressure plate, rendering it useless.

3. Gradually unscrew the six 6mm bolts that hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time.
4. Remove or disconnect the following:
   • Clutch plate and disc
   • 2 retaining springs, the throwout bearing and the release fork

   NOTE: Do not disassemble either the clutch cover or disc. Inspect the parts for wear or damage and replace any parts as necessary. Replace the clutch disc if there is any oil or grease on the facing. Do not wash or attempt to lubricate the throwout bearing, because it is sealed and permanently lubricated. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.

   To install:

5. Fit the release fork boot on the front of the transmission housing.
6. Install or connect the following:
   • Release fork
   • Throwout bearing assembly and secure it with the 2 springs

   NOTE: Coat the inside diameter of the throwout bearing and the release lever contact points with grease.

   • Clutch alignment tool through the clutch cover and disc, then insert the end of the tool into the needle bearing

     Fig. 1: Clutch cover alignment and tightening sequence

7. Tighten the pressure plate bolts following the illustrated sequence, 1 turn at a time, until the proper torque is reached. Tighten to 12 ft. lbs. (16 Nm).

   WARNING
   When installing the clutch pressure plate assembly, be sure that the

   O marks on the flywheel and the clutch pressure plate assembly are at least 120 degrees apart. These marks indicate the direction of residual unbalance. Also, be sure that the clutch disc is installed properly, noting the FRONT and REAR markings.

8. Install the transmission.