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clutch
cover to
inside diameter clearance
IS
more
then 0 5
mm
0 2
In
If
excessive
grease has leaked from the
beanng
It
should be
replaced
To
remove
the
beanng
use a
conventional
two
arm
puller
as
shown
In
Fig
F 12
The
bearing
should
be
pressed
on
uSing
a
force of 400
kg 880
Ibs
When pressing
on
the
bearing
for the
diaphragm
spnng
type
excert
the
pressure
on
the
outer
race
as
shown
In
Fig
F 13 In the
case
of the coil spnng
type
the pressure must
be
excerted
on
the
Inner
race
as
In
Flg
F 14 After
assembly
check the
bearing
for smooth
rotation
CLUTCH
Assembly
Call spring
type
Press the pin
Into
the
eyebolt
and
through
the pressure
plate
lug
Place three distance pieces
on
the surface of the base
plate
and arrange pressure
plate
pressure spnngs and
retainers
on
the
plate
Set the retracting springs
on
to
the
cover
and fit the
release levers
through
the springs
Place the clutch
cover
over
the pressure
plate
and the springs
observing
that the pressure
springs
are
not
dislodged
and
not
hable
to
distortion
Then
tighten
the
cover
bolts
gradually
In
a
diagonal
pattern
to
compress the pressure spnngs
Place the release levers
over
the
eyebolts
and
screw
on
the
secunng
nuts
Lock
the
eyebolt
nuts
after
adjustment
deSCribed below
Push retaining hooks under the release levers
and
remove
the clutch
assembly
from the base
plate
slackening
the bolts
In a
diagonal
pattern
to
avOid distortion
CLUTCH
Adjustment
Call spring
type
USing
the
height
gauge
on
the
centre
pillar
loosen
or
tighten
the
eyebolt
nuts
so
that the
tops
of the release levers
are
JUst
touching
the tip of the gauge
Fig
F 15
When all three levers
are
correctly adjusted
remove
the
centre
pillar
and
screw
In
the
actuating
lever
F Ig F 16
Operate
the
clutch
mechanism
several
times
and
re
check the release lever setting
as near
to
the
edge
as
poSSible
If the deViation
IS more
than 04
mm
0016
In
re
adJust
the levers
as
necessary
Finally
secure
the
eyebolt
nuts
by
peening
over
the matenal
CLUTCH
Installation
With the
long
chamfered
end of the clutch dnven
plate sphnes
facing
the
gearbox place
the clutch
on
to
the
flywheel
Use
a
spare clutch shaft
ahgn
the clutch dnven
plate by
Inserting the
shaft
through
the dnven
plate
and
Into
the
pilot
beanng
of the
flywheel
crankshaft
Turn the clutch
cover
In
order
to
bnng
In
hne the holes for the clutch bolts
In
the
cover
With the threaded
holes
In
the
flywheel
and
tighten
the bolts
In a
diagonal
manner
gradually
to a
torque
of 24
26
kgm
174
188 Ib ft
Remove the
dummy
shaft Do not
forget
to
remove
the
clutch
spring
restnllmng
hooks from under the release leversl Fit the
release
bearing
and the bell
hOUSing
CLUTCH PEDAL
Removal 8IId Installation
Remove the cleviS pin
from
the end
of
the
push
rod and
disconnect the
push
rod
end
Remove the
return
spnng
the
push
rod and the
push
rod
adjuster If
fitted
Remove
the
pedal
lever securing
bolt
loosen the handbrake bracket secUring bolts
and
11ft
out
the
pedal
Clean all
parts
and
check
for
wear
With
special
note
to
rubber
parts
return
spring
and
pedal
lever bush
Replace
parts
as
necessary
The installation of the clutch
pedal
IS
a
reversal of
the removal
procedure
CLUTCH PEDAL
Adjustment
With the
pedal
stop bracket free
adjust
the
pedal height
to
183
mm
7 205
In
for R H D
models and 208
mm
8
189
In
for
L H 0
models
by adjusting
the
length
of the master
cylinder
push
rod Then
tightening
the
pedal
stop bracket obtain
a
pedal
height
of 182
mm
7 165
In
for R H D
models
or
207
mm
8 150
In
for L H 0 models and lock the
stop
bracket
AdjUst
the
length
of the
assist
spnng
push
rod
to
203
mm
7992
In
for R H D
models and 183
mm
7205
In
for
L H 0
models
by
rotating the
push
rod
adjuster
only
fitted
With COil Spring type clutch
CLUTCH MASTER
CYLINDER
Removal
Remove the
push
rod cleVIS Pin disconnect the clutch hose and
dram the flUid
Remove the
cyhnder
secunng bolts and hft
out
the
cyhnder
CLUTCH
MASTER
CYLINDER
Dlsmanthng
Fig
F 18
Empty
the flUid from the
reservoir
pull
back the rubber dust
cover
and
remove
the
clrchp
Withdraw the
push
rod
together
With the retaining nng
Unscrew the piston stop
screw
and
remove
the
complete
piston assembly
The
piston
can
be
dismantled
by
lifting
the spnng seat
over
the
piston
shoulder
Clean all
parts
In
brake flUid
Any
damaged
or
abnormally
worn
parts
should be
replaced
The
maximum
permissible
clearance
between
piston
and
cyhnder
must not
exceed 0 13
mm
0005
m
and
as a
matter
of
pohcy
the
piston
cup should be
replaced
every
time
If the piston sprmg
or
valve spnng
IS
weak
replace
them
CLUTCH MASTER CYLINDER
Assembly
ThiS
IS a
reversal of the
dlsmanthng procedure
All moving parts
should be lubncated With brake flUid The
piston
cup should be
soaked
In
brake flUid pnor
to
assembly
CLUTCH MASTER CYLINDER
Installation
The
installation of the
master
cyhnder
IS
a
reversal of the
removal
procedure
Take
care
that the threads of the clutch
hose
are
not
damaged
Check the
pedal height
and
adjUst
If
necessary
as
descnbed earher
on
Finally
bleed the clutch
hydraulic
system
CLUTCH
SLAVE CYLINDER
Removal
Fig
F 19
Disconnect the flUid line from the slave
cylinder
and the
push
rod from the clutch
withdrawal
lever Remove the
two
cylinder
mounting
bolts and hft
out
the
cyhnder
CLUTCH SLAVE
CYLINDER
Dismantling
After removal of the rubber dust
cover
and
the
clrclip
all
parts
of the slave
cyhnder
can
be
eaSily
removed
Check
all parts
for
39
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