REMOVAL & INSTALLATION
See Figures 1 through 10
- Lift the clutch pedal to its uppermost position to disengage the pawl and quadrant. Push the quadrant forward, unhook the cable and allow the quadrant to slowly swing rearward.
- Raise and safely support the vehicle.
- Remove the dust cover from the flywheel/clutch housing and disconnect the clutch cable from the release lever.
- Unfasten the retaining clip and remove the clutch cable from the flywheel housing.
- Disconnect the starter electrical cable and remove the starter motor from the flywheel housing.
- Remove the transmission and driveshaft, as described earlier in this section.
- Remove the bolts securing the engine rear cover plate to the front lower portion of the flywheel housing. Remove the flywheel/clutch housing.
- Remove the clutch release lever from the housing by by pulling it through the housing window until the retainer spring is disengaged from the pivot.
- Separate the release bearing and hub from the release lever.
- Matchmark the pressure plate and flywheel to facilitate reassembly in the same position. Loosen the six pressure plate attaching bolts evenly to release the spring pressure.
- Remove the six attaching bolts while holding the pressure plate. Remove the pressure plate and clutch disc.
- Before installing the clutch, clean the flywheel surface. Inspect the flywheel and pressure plate for wear, warpage, scoring, or burn marks (blue color). Light scoring and wear may be cleaned up with emery paper; heavy wear may require refacing of the flywheel or replacement of the damaged parts.
- Attach the clutch disc and pressure plate assembly to the flywheel. The three dowel pins on the flywheel, if so equipped, must be properly aligned. Damaged pins must be replaced. Avoid touching the clutch plate surface. Tighten the bolts finger tight.
- Insert a clutch alignment arbor and align the clutch disc with the pilot bushing. Torque the pressure plate retaining bolts to 12-24 ft. lbs. (17-32 Nm) in a cross-wise pattern. Remove the clutch alignment arbor.
- Lightly lubricate the release bearing retainer journal, using Multi-Purpose Long-Life Lubricant (part no. C1AZ-19590-B) or equivalent. Fill the groove in the release bearing hub with the same grease. Clean all excess grease from the inside bore of the hub to prevent clutch disc contamination.
- Attach the release bearing and hub to the release lever.
- Lightly lubricate the release lever ball and pocket with the aforementioned lubricant.
- Lightly lubricate the outside diameter of the transmission front bearing retainer with the same lubricant.
- Install the release lever and bearing assembly in the flywheel housing.
- Inspect the flywheel housing dowel holes for misalignment and wear. Also check that the dowels are in good condition; missing or damaged dowels must be replaced.
- Install the flywheel housing and the bolts which secure the the engine rear cover plate to the front lower portion of the flywheel housing.
- Install the transmission and driveshaft, as described earlier in this section.
- Connect the clutch cable to the flywheel housing and fasten the retaining clip.
- Connect the clutch cable to the release lever and install the dust cover.
- Install the starter motor and connect the starter electrical cable.
- Install the clutch cable assembly by lifting the clutch pedal to disengage the pawl and quadrant, pushing the quadrant forward and hooking the end of the cable over the rear of the quadrant. Cycle the clutch pedal several times to adjust the cable.