Clutch Installation

- Check and, if necessary, replace clutch parts prior to installation.





- Prior to installation push intermediate ring at the three adjusting elements in direction of the release bearing.
3 = Adjusting element





- Assemble clutch (hubs of discs face release bearing. Service and Repair-- Clutch Assembly
- Guide clutch into clutch housing and center discs with drive shaft in grooved ball bearings of crankshaft.





NOTE:
^ The discs are different. Disc I (sometimes marked with white paint dot) is between flywheel and intermediate ring. Disc II (larger liner springs or longer hub) is between pressure plate and intermediate ring .
^ When installing discs on short central shaft make sure residual unbalance sides (yellow arrow/black side) are offset 180° opposite each other.

- Note marks when installing pressure plate, intermediate ring and flywheel. Guide centering pins of a dowel pin centered clutch into the flywheel.
- Insert mounting bolts.
Screw in clutch mounting bolts uniformly until the clutch is held tight.





Make sure that central shaft moves easily. Then remove the clips from underneath the pressure plate bolt heads.

NOTE: Differences in tolerances could make it difficult to guide in the dowel pin-centered clutch. Should this apply, position the centering pins as for removal. Guide in clutch and insert mounting bolts. Drive in centering pins after they have been aligned with the flywheel bores (reposition pressure plate for this purpose). After tightening the mounting bolts, drive in centering pins until they are flush with the pressure plate.





1 - Intermediate ring housing
2 - Intermediate ring stop
3 - Adjusting element
4 - Fork
5 - Gap of 0.7 to 1.0 mm or 1.2 to 1.5 mm
6 - Position of fork on stop
A - Release bearing side
S - Flywheel side

- The forks of the stop brackets must rest on the stop of the intermediate plate on the flywheel end on both sides. This will produce a gap of 0.7 to 1.0 mm or 1.2 to 1.5 mm (see sketch).





- Push back the 3 forks of the stop brackets uniformly on both sides with a screwdriver (in direction of pressure plate). This alone will guarantee proper function of the clutch and stop brackets.
- Mount release bearing sleeve.
Connect release lever at ball stud. Place ball stud and ball socket opposite each other and press down release lever toward the rear until the lever engages.
First mount coupling on central shaft. Center bores of coupling on shafts accurately. Install cover for clutch bell housing and slave cylinder.

NOTE: Location of slave cylinder piston rod can be checked through inspection hole.

- Install lower body brace, if applicable, positioning correctly. Protruding support plate on lower body brace must face forward to cover for clutch bell housing.