REMOVAL & INSTALLATION
- Raise the car.
- Remove the transmission.
- Remove the throwout bearing from the clutch fork by sliding the fork off the ball stud against spring tension. If the ball stud is to be replaced, remove the locknut and stud from the bellhousing.
- If the balance marks on the pressure plate and the flywheel are not easily seen, remark them with paint or centerpunch.
- Alternately loosen the pressure plate-to-flywheel attaching bolts one turn at a time until spring tension is released.
- Support the pressure plate and cover assembly, then remove the bolts and the clutch assembly.
- Align the balance marks on the clutch assembly and flywheel. Place the clutch disc on the pressure plate with the long end of the splined hub facing forward and the damper springs inside the pressure plate. Insert a used or dummy shaft through the cover and clutch disc.
- Position the assembly against the flywheel and insert the dummy shaft into the pilot bearing in the crankshaft.
- Align the balance marks and install the pressure plate-to-flywheel bolts finger-tight.
- Pack the groove on the inside of the throwout bearing with graphite grease. Coat the fork groove and ball stud depression with the lubricant.
- Install the throwout bearing and release fork assembly in the bellhousing with the fork spring hooked under the ball stud and the fork spring fingers inside the bearing groove.
- Position the transmission and clutch housing and install the clutch housing attaching bolts and lockwashers. Tighten the bolts to 25 ft. lbs. (33 Nm).
- Complete the transmission installation.
Check position of the engine in the front mounts and realign as necessary.
A special gauge (part no. J-28449 or its equivalent) is necessary to adjust the ball position.
- Perform Initial Ball Stud Adjustment and Clutch Cable Attachment and Adjustment. Adjust clutch pedal free-play if necessary.
- Lower the car and check operation of the clutch and transmission.
- Remove the transmission as described in this section.
- Mark the clutch assembly to flywheel so that it can be installed in the original position.
- Install aligning Tool J-24547 or an appropriate dummy shaft through the pressure plate and disc.
- Remove the release bearing to fork retaining springs and remove the release bearing with the support.
- Remove the shift fork from the transmission ball stud.
- Installation is the reverse of removal. Install the clutch assembly in the original position while aligning with Tool J-24547 or equivalent. Tighten the bolts evenly to 14 ft. lbs.
INITIAL BALL STUD ADJUSTMENT
4- and 5-Speed Gas Engine
- Install throwout bearing assembly, release fork, and ball stud to the transmission.
- Install and secure the transmission to the engine.
- Cycle the clutch once.
- Place the special gauge (Part No. J-28449) so that the flat end is against the front face of the clutch housing and the hooked end is located at the bottom depression in the clutch fork.
- Turn the ball stud inward by hand until the throwout bearing makes contact with the clutch spring.
- Install the locknut and tighten it to 25 ft. lbs. (33 Nm), being careful not to change the ball stud adjustment.
- Remove the gauge by pulling outward at the housing end.
CLUTCH CABLE ATTACHMENT AND ADJUSTMENT
These adjustments are made before the return spring is installed and with the clutch cable attached to the clutch pedal at its upper end.
- Place the clutch cable through the hole in the clutch fork.
- Pull the clutch cable until the clutch pedal is firmly against the pedal bumper and hold it in position.
- Push the release fork forward until the throwout bearing contacts the clutch spring fingers and hold it in position.
- Thread the nut or the cable until it bottoms out against the spherical surface of the release fork.
- Depress the clutch pedal to the floor a minimum of 4 times to establish cable position at clearance points.
- To obtain the correct clutch pedal lash, use either Step 7 or Step 8.
- See View A of the accompanying illustration.
- Place a 4.35mm thick gauge or shim stock against surface D of nut B.
- Thread the locknut on the cable A until the locknut contacts the gauge.
- Remove the gauge and back off nut B until it contacts the locknut.
- Tighten the locknut to 4 ft. lbs.
- See View B of the accompanying illustration.
- Turn nut B 4 turns counterclockwise.
- Thread the locknut on the cable A until the locknut contacts nut B. .
- Tighten the locknut to 4 ft. lbs.
- Attach the return spring.
- This procedure should yield 21mm - 6mm lash at the clutch pedal.
The following adjustments are to be made with the cable and loose parts assembled to the front of the dash and the cable attached to the clutch pedal.
- Place the cable through the hole in the clutch fork and properly seat it.
- Install the return spring.
- From the engine compartment, pull the cable away from the dash until the clutch pedal is firmly seated against the pedal bumper.
- Holding the pedal in position, install the circlip in the first fully visible groove in the cable from the sleeve. Release the cable.
- Depress the clutch cable at least 4 times to make sure that all the elements are properly seated.
- This procedure should produce a lash of 21mm - 6mm at the clutch pedal.
If the above procedure produces excessive pedal lash, remove the circlip from the cable and move it into the dash by one ring. If the lash is insufficient remove the circlip and move it away from the dash one ring.
CLUTCH PEDAL FREE-PLAY ADJUSTMENT
Adjustment for normal wear is made by turning the release fork ball stud counterclockwise to give 21mm - 6mm lash at the clutch pedal.
- Loosen the locknut on the ball stud end located to the right of the transmission on the clutch housing.
- Adjust the ball stud to obtain the correct free-play (lash) as mentioned previously.
- Tighten the locknut to 25 ft. lbs., being careful not to change adjustment.
- Check for proper clutch operation.
- If there is insufficient play in the pedal, remove the circlip from the cable and allow the cable to move into the dash by one notch. Reinstall the circlip.
- If there is excessive pedal lash, remove the circlip and pull the cable