Clutch Removal

- Disconnect ground strap at battery.





- Remove TDC sensor on clutch housing by taking off air cleaner, loosening screw and pulling TDC sensor out of clutch housing. Pull speed reference mark sensor for electronic ignition out of crankcase upper section while turning back and forth, after loosening the screw.

- Remove lower body brace, if applicable.
- Unscrew clutch slave cylinder, remove clamp on clutch hose holder and take out cylinder with line connected.

NOTE: Clutch must not be operated as long as slave cylinder is removed.





- Remove starter or loosen starter and suspend it from car. Take off clutch housing cover. Remove converter (modified shape).





- Remove coupling screws and push back coupling on central shaft. Remove plug from central tube to unscrew rear bolt.





- Remove release bearing sleeve mounting bolts and push sleeve toward flywheel.
- Mark position of pressure plate, intermediate plate and flywheel in relation to each other for installation later.
- one of the three centering pins is stepped (6 mm diameter in area of intermediate ring/pressure plate and 8 mm diameter in flywheel). Consequently the intermediate ring can only be installed in a certain position to the flywheel.





- Remove stepped centering pin (large bore in flywheel) completely. This is only possible in direction of the flywheel.
- Drive the other two centering pins in direction of pressure plate as described above, until they are beyond the centering bore of the flywheel (do not remove completely).
- Unscrew the clutch mounting bolts one after the other by 1 to 1 1/2 turns until pressure is removed from the pressure plate. Disconnect release lever at ball stud, by pushing the release lever down toward the flywheel. Now remove the mounting bolts.





NOTE: The pressure plate remains pre-loaded and removal will be easier by using 4 mm thick wire brackets (locally made) underneath the bolt heads before loosening the mounting bolts (less force required/brackets bevelled). In addition, it will not be necessary to unscrew the mounting bolts in steps of 1 to 1 1/2 turns.





- Push back entire clutch (pressure plate, intermediate ring with starter gear ring, both clutch discs, release lever, release bearing sleeve, central shaft ) and remove downward.