Fig. Fig. 1 Exploded view of the clutch assembly
Fig. Fig. 2 Clutch release bearing lubrication points-flat finger type (top), bent finger type (bottom)
Fig. Fig. 3 Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...
Fig. Fig. 4 ... then carefully remove the clutch and pressure plate assembly from the flywheel
Fig. Fig. 5 View of the flywheel once the clutch assembly is removed
Fig. Fig. 6 Check across the flywheel surface, it should be flat
Fig. Fig. 7 If necessary, lock the flywheel in place and remove the retaining bolts ...
Fig. Fig. 8 ... then remove the flywheel from the crankshaft in order replace it or have it machined
Fig. Fig. 9 Upon installation, it is usually a good idea to apply a thread-locking compound to the flywheel bolts
Fig. Fig. 10 Check the pressure plate for excessive wear
Fig. Fig. 11 Be sure that the flywheel surface is clean, before installing the clutch
Fig. Fig. 12 Typical clutch alignment tool, note how the splines match the transmission's input shaft
Fig. Fig. 13 Install a clutch alignment arbor, to align the clutch assembly during installation
Fig. Fig. 14 Clutch plate installed with the arbor in place
Fig. Fig. 15 Clutch plate and pressure plate installed with the alignment arbor in place
Fig. Fig. 16 Pressure plate-to-flywheel bolt holes should align
Fig. Fig. 17 You may want to use a thread locking compound on the clutch assembly bolts
Fig. Fig. 18 Install the clutch assembly bolts and tighten in steps, using an X pattern
Fig. Fig. 19 Be sure to use a torque wrench to tighten all bolts
Fig. Fig. 20 View of the clutch and pressure plate assembly
Fig. Fig. 21 Grease the clutch release fork ball
Fig. Fig. 22 Grease the throwout bearing assembly at the outer contact points
Fig. Fig. 23 If equipped, install the clutch release fork bearing clip
Fig. Fig. 24 View of the clutch release fork assembly installed, be sure all parts move freely
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. NEVER clean the clutch surfaces with compressed air! Avoid inhaling dust from the clutch surface! When cleaning the clutch surfaces use a commercially available brake cleaning fluid.
Support the engine and remove the transmission.
Disconnect the clutch fork pushrod and spring.
Remove the flywheel housing.
Slide the clutch fork from the ball stud and remove the fork from the dust boot. The ball stud is threaded into the clutch housing and may be replaced, if necessary.
Install an alignment tool to support the clutch assembly during removal. Mark the flywheel and clutch cover for reinstallation, if they do not already have
Loosen the clutch-to-flywheel attaching bolts evenly, one turn at a time, until spring pressure is released. Remove the bolts and clutch assembly.
Clean the pressure plate and flywheel face.
Support the clutch disc and pressure plate with an alignment tool. The driven disc is installed with the damper springs on the transmission side. On some 6-cylinder engines, the clutch disc is installed in the reverse manner with the damper springs to the flywheel side.
Turn the clutch assembly until the mark on the cover lines up with the mark on the flywheel, then install the bolts. Tighten down evenly and gradually to avoid distortion.
Remove the alignment tool.
Lubricate the ball socket and fork fingers at the release bearing end with high melting point grease. Lubricate the recess on the inside of the throwout bearing and throwout fork groove with a light coat of graphite grease.
Install the clutch fork and dust boot into the housing. Install the flywheel housing. Install the transmission.
Connect the fork pushrod and spring. Lubricate the spring and pushrod ends.
Adjust the shift linkage and clutch pedal free-play.