The engine and transmission must be removed as a unit and than separated in order to service the clutch. It is normally recommended that the pressure plate and release bearing be replaced when a new clutch disc is installed.
The flywheel and the transmission pilot shaft bearing should be carefully inspected when replacing the clutch. Replacing the clutch disc without replacing other worn components may accelerate clutch disc wear.
— Remove engine/transmission from car. Separate engine from transmission. See 101 Engine Removal and Installation).
— Insert clutch alignment tool into center of clutch.
Loosen 9 bolts (arrows) holding clutch assembly to flywheel.
To avoid warping the pressure plate, loosen bolts evenly, one turn at a time, until clutch pressure is relieved.
— Once bolts have been loosened, remove all 9 bolts. Remove starter ring gear and clutch.
The clutch disc contains asbestos fibers. Breathing asbestos dust can cause asbestosis. Always wear an approved respirator and protective clothing when handling components containing asbestos. Do not use compressed air, do not grind, heat, weld or sand on or near any asbestos materials. Only approved cleaning equipment should be used to service the clutch disc or areas containing asbestos dust or asbestos fibers.
— Check components for wear and damage. Repair or replace as needed.
• Check starter ring-gear teeth.
• Check release bearing guide tube.
Check flywheel face for damage.
• On 1984-1986 models: If damaged or scored, machine to specifications.
• On 1987-1989 models: If damaged or scored, replace.
1984-1986 Flywheel Service Specifications
• Machining limit minimum needed for smooth surface
— Check for signs of oil at bottom of transmission or in bell-
housing. If found, inspect engine and transmission oil seals.
• To replace transmission input shaft seal, see 340 Manual Transmission-Controls and Case.
• To replace engine rear main seal (also referred to as the rear crankshaft oil seal), see 130 Crankcase and Crankshaft.
^ Check transmission pilot shaft bearing:
• On 1984-1986 models: Pilot bearing is lightly pressed into center of flywheel.
• On 1987-1989 models: Pilot bearing is held by three bolts to holes (arrows) at rear end of crankshaft.
• Replace bearing if dry or worn out.
• Lubricate bearing with a multipurpose grease.
— Place new release bearing on pressure plate as described later.
^ Using special clutch disc alignment tool P 370, mount clutch assembly to flywheel. Tighten clutch bolts uniformly one turn at a time.
— Prior to installing transmission on engine, lubricate transmission input shaft splines with Optimoly® HT or equivalent. Lubricate release bearing guide tube with multipurpose grease containing molybdenum disulfide (MoS2).
— On 1984-1986 models: As transmission slides onto the engine studs, turn clutch cross-shaft so that clutch fork hooks into release bearing.
^ On 1987-1989 models: Prior to installing transmission, use duct tape or equivalent to hold clutch release fork on release bearing (arrow).
— Install engine to transmission nuts and torque.
^ On 1987-1989 models: Install clutch cross-shaft (arrow), making sure it engages clutch fork inside bellhousing.
Remove the adhesive tape used to keep the clutch release fork in place through the hole in the side of the bellhousing.
— Install engine/transmission as described in 101 Engine Removal and Installation.
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