1. Pilot bearing and flywheel installations were detailed
previously in respective service sections. As a prelim-
inary step, recheck the pilot bearing and flywheel to
make sure they are installed properly.
2. Install the clutch disc and pressure plate assembly
onto the flywheel. If one side of the disc is marked
flywheel, place that side against the flywheel. If not
marked, study the disc, flywheel, and assembly to
determine which way the long side of the hub should
fit into the assembled clutch. It should be fairly obvi-
ous. Use your alignment tool, Figure 7-35. It will hold
the disc in place and keep the disc hub aligned with
the pilot bearing. This way, the input shaft will go in
smoothly when you attempt to reinstall it.
Caution: When handling clutch parts, make
sure your hands are clean. It is important
that no oil or grease contact the clutch disc.
Match holes in the assembly to flywheel dowels,
where applicable. Otherwise, align punch marks that
you made during removal. Some pressure plate
assemblies will be aligned through offset bolt holes. If
none of these reference marks are available, turn the
pressure plate assembly on the alignment tool and
align bolt holes with the nearest threaded holes in the
flywheel.
3. Begin threading in the clutch cover attaching bolts.
Install two directly opposite each other, finger-
tightening them. The clutch will now support itself.
Thread in and finger-tighten the remaining bolts,
making sure all bolts are started properly.
Caution: The bolts used to hold the pres-
sure plate assembly to the flywheel are
high-strength bolts. Do not use low-tension
“hardware-store” replacements, as they will probably
break and cause a clutch explosion.
Finish tightening the clutch cover attaching bolts by
torquing them down gradually in a crisscross pattern.
Make sure the pilot shaft does not sag as you tighten
the bolts. Putting a slight upward force on the pilot
shaft will help to retain the alignment of the clutch
disc. Finish tightening the bolts to the proper torque
given by the manufacturer. Once the bolts are tight-
ened, make sure the clutch pilot shaft slides in and
out freely. See Figure 7-36.
4. If so equipped, lubricate the seat of the clutch fork ball
stud in the clutch housing. Use high-temperature
grease. Install the spring clip in the fork. Force the ball
stud into the fork recess so that it is engaged by the clip.
If the clutch fork is the shaft type, assemble by pass-
ing the release shaft through the clutch housing and
clutch fork. Lubricate the parts as necessary and lock
them in place with the retaining E-clip. If lock bolts
are used, be sure to torque them properly.
Chapter 7 Clutch Problems, Troubleshooting, and Service 151
A
B
Transmission
Front bearing
retainer hub
Clutch
release
bearing
E-clip
Bushing
Screwdriver
Clutch
release
shaft
Clutch
release
fork Bushing
Clutch
release fork
Clutch
release lever
Clutch release
shaft
E-clip
Figure 7-34. This type of clutch fork uses a shaft mounting. It
must be disassembled to remove the fork.When the shaft is out
of the housing, it should be checked for wear. A—Remove the
retaining E-clip. B—Remove the clutch release shaft.
(DaimlerChrysler)
Flywheel
Pressure plate
assembly
Clutch
alignment
tool
Clutch disc
Figure 7-35. Study the relative position of the clutch parts and
the clutch pilot shaft. Use of a clutch pilot shaft will make trans-
mission reinstallation much easier. (General Motors)