NV3500 Manual Transmission

CLUTCH ASSEMBLY AND PILOT BEARING REPLACEMENT

TOOLS REQUIRED:
- J 5824-01 Clutch Alignment Tool
- J 23907 Pilot Bearing Puller
- J 38149 Universal Puller

Clutch Assembly And Pilot Bearing:

Clutch Assembly (Dual Mass Flywheel):

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Actuator cylinder.
- Hydraulic tube and clips.
3. Inspection cover to clutch housing bolts.
4. Inspection cover from the clutch housing.
5. Clutch housing to the engine studs.
6. Transmission from the engine.
7. Spring, seat, and clutch fork.
8. Clutch fork inspection plug.

IMPORTANT:
- Install J 5824-01 or a used clutch drive gear to support the clutch.
- Mark the flywheel, clutch cover, and a pressure plate lug for alignment during installation.

9. Bolts and spring washers from clutch cover.

IMPORTANT: Loosen each bolt one turn at a time to avoid warping the clutch cover.

10. Cover assembly and driven plate.
- Remove the clutch alignment tool

Clutch Assembly And Pilot Bearing:

11. Pilot bearing if it is worn or damaged. Use J 23907 or J 38149 as needed.

CLEAN
1. All parts with a clean, water dampened cloth to remove any fibers.
2. Clutch fork, clutch housing, and ball stud with solvent Wipe dry.

NOTICE: The release bearing is permanently packed with lubricant and should not be soaked in cleaning solvent since this will dissolve the lubricant.

INSPECT
- All parts for wear and damage.
- Contact surfaces for scoring and flatness with a straight edge.
- Friction pads for scoring, gouges, and loose rivets. Check to see if they are oil soaked.
- All splines for nicks, burrs, and sliding fit.
- All springs for bending and breaks.
- Boot for tears and brittleness.

MEASURE
- Transmission pilot hole in the clutch housing for runout using a dial indicator. Runout should not be more than 0.380 mm (0.015 inch).

Clutch Assembly And Pilot Bearing:

Clutch Assembly (Dual Mass Flywheel):

INSTALL OR CONNECT

TOOL REQUIRED:
- J 5824-01 Clutch Alignment Tool
- Brass Drift or Equivalent

1. New pilot bearing if needed. Use Brass Drift or J 34140 as needed to drive the bearing in until the tool bottoms out.
- Lubricate the bearing with a few drops of machine oil.

2. Driven plate and cover assembly.

IMPORTANT:
- Install J 5824-01 or a used clutch drive gear to support the clutch.
- Align the marks made during removal or, if new, align the lightest part of the clutch cover, identified by a yellow dot, to the heaviest part of the flywheel, identified by an "X".

3. New spring washers and bolts.

IMPORTANT: Tighten each bolt one turn at a time to avoid warping the clutch cover.

TIGHTEN
- Clutch cover bolts to 41 Nm (30 lbs. ft.).
- Clutch cover bolts (dual mass flywheel) to 34 Nm (25 lbs. ft.).
- Remove the clutch alignment tool.

NOTICE: Be careful not to use too much lubricant. Excessive lubricant may get on the clutch disc and cause slippage, or damage may result to the clutch.

4. Ball stud.
- Coat the rounded end of the ball stud with high temperature grease.
- Pack the ball stud from the lubrication fitting on the clutch housing.

(Figure 4.) Release Bearing:

5. Release bearing and clutch fork.
- Pack the inside recess (A) and outside groove (B) of the release bearing with high temperature grease as shown.
- Release bearing to the clutch fork.

IMPORTANT: Bearing retainer spring should be depressed and rest within groove (B) of the release bearing.

6. Seat and retainer.

TIGHTEN
- Clutch housing studs to 31 Nm (23 lbs. ft.).

7. Transmission to engine.
8. Inspection cover and bolts.

TIGHTEN
- Inspection cover bolts to 12 Nm (106 lbs. in.).

9. Actuator cylinder.
- Hydraulic tube and clips.
- Remove clutch fork inspection plug to make sure push rod is properly seated in the fork.

10. Clutch fork inspection plug.

TIGHTEN
- Inspection plug to 7.5 Nm (66 lbs. in.).

11. Negative battery cable.