Clutch Installation

- Check flywheel, starter gear ring, pilot bearing in flywheel, crankshaft seal, release bearing, guide sleeve, release lever, pressure plate and clutch disc for wear or damage.
- Coat guide sleeve with multi-purpose MoS2 grease. Give spline of drive shaft and area in pilot bearing/flywheel a light coat of MoS2. Lubricate release lever (pivot, ball socket and needle bearings) with white solid lubricating paste AOS 126 0006.





- Install clutch. This requires that friction surfaces be clean and without grease. Use short drive shaft of a 928 (or a shortened drive shaft from a damaged central tube) to center the clutch disc. Screw in bolts uniformly crosswise. Counterhold on hexagon bolt of front pulley.
^ Tightening torque = 25 Nm (18 ft lb)
- Mount clutch housing and release lever together with release bearing to engine. This requires that the bolt glued on the flywheel for the reference mark sensor faces down (danger of damage). Insert cover. Mount clutch housing with the two lower bolts.
- Move release lever until needle bearing and bore in clutch housing align.
- Slide in release lever shaft positioned correctly so that machined surface faces mounting bolt against stop. If necessary, move release lever back and forth - but never use force!





- Screw in mounting bolt for a correctly installed release lever shaft and lock with nut.
^ Tightening torque = 9.5 Nm (7.0 ft lb)
- Bolt clutch housing, cover and, if applicable, right support.
^ Tightening torque = Clutch housing 75 Nm (55.3 ft lb)
Right support 42 Nm (30.9 ft lb)
- Connect starter wire harness. Mount start and reference mark sensors as well as ground wires on clutch housing and body.
^ Tightening torque = 8 Nm (5.9 ft lb)
- Check that insulation sheet on central tube is still positioned correctly. Distance from flange inside to insulation should be 500 mm (20 in.).





- Push central tube forward and bolt to clutch housing.

Caution: Guide central tube with drive shaft into clutch housing and clutch disc carefully (danger of damage). Never apply force.

- Screw in mounting bolts and loosen again by about 1 turn. (Never tighten bolts fully, see note!)

NOTE: To avoid tension in engine, transmission and central tube, when installing in car tighten central tube to clutch housing mounting bolts only after securing the engine and transmission.

- Install clutch slave cylinder.
^ Tightening torque = 21 Nm (15.4 ft lb)
- Mount clutch line.





- Place selector rod protective tube in transmission case. Replace selector rod protective tube if the retainer is deformed excessively.
- Install transmission.
- Push selector rod protective tube forward until retainer engages in transmission case. Mount selector rod on intermediate shift lever.
- Tighten mounting nuts insofar as engine mounts had been unscrewed.
^ Tightening torque = 30 Nm (22.1 ft lb)
- Then bolt central tube on clutch housing (bolts had only been screwed in finger tight).
^ Tightening torque to clutch housing:
M10 x35 -- 42 Nm (30.9 ft lb)
^ Tightening torque to transmission case:
M12 x 75 -- 85 Nm (62.6 ft lb)
M12 x 80 -- 85 Nm (62.6 ft lb)
M10 x 60 -- 42 Nm (30.9 ft lb)
- Repair any damage on splash guard caused by removal of transmission or moving of central tube. Install starter and exhaust assembly.





- Mount shift lever so that inclination in neutral is 85° (refer to mark).