Clutch: Service and Repair

1. Remove transmission as described under "Transmission, Replace."
2. With suitable clutch disc guide inserted in center hole to prevent clutch disc from dropping, evenly loosen bolts holding clutch cover assembly in a crossing pattern, then remove clutch cover assembly.
3. Remove clutch disc.
4. Remove return clip on transmission side, then remove release bearing carrier and bearing.
5. Using a suitable punch, remove shift arm spring pin and control lever shaft assembly, then remove clutch shaft arm, two felt packings and return springs.
6. Insert clutch control lever and shaft assembly into transmission case from left side, then install clutch shift arm, two felt packings and two return springs onto shaft. Apply grease to inside surface of bushing and oil seal lips. Apply engine oil to felt packings.

Fig. 5 Clutch release lever & shaft installation:

7. Align lock pin holes of shift arm and control shaft, then drive in two spring pins using lock pin installer MD998245. When driving in spring pins, ensure spring pin slot direction is at right angles to centerline of control shaft.
8. Apply suitable grease to clutch disc spline and main drive gear spline.
9. Using suitable clutch disc guide tool, install clutch disc and clutch cover on flywheel. Install clutch disc with manufactures stamped mark facing pressure plate. When installing clutch cover, align flywheel and clutch cover notches to ensure proper balance.
10. Install release bearing and carrier, then install return clip. Apply grease to inside diameter of carrier and fill groove with grease.
11. Install transmission, then adjust clutch pedal as described under "Clutch Pedal, Adjust."