CAUTION! YOUR PRESSURE PLATE IS ASSEMBLED UNDER SPRING TENSION, SOME AS HIGH AS 2800 POUNDS. USE EXTREME CARE WHEN WORKING ON THIS UNIT. YOUR FLYWHEEL MUST HAVE PRESSURE PLATE TO FLYWHEEL STUDS (PN 492) TO PERFORM THIS WORK.
1. Remove the entire clutch assembly including the flywheel. On the bench, place the disc on the friction surface of the flywheel and bolt the pressure plate down.
2. Carefully loosen the three- 3/8-24 bolts on the top of the cover that hold the levers in place. As you take the bolts out, the levers will drop in towards the clutch disc. Note the shims between the lever yoke and the cover. These are used to adjust the levers.
3. The next step is to relieve the spring pressure and remove the cover. Start to loosen the six nuts bolting the cover to the flywheel. Do this evenly, a few turns at a time, working your way around the cover until the spring pressure is relieved. Take the nuts off and remove the cover. Remove the springs and adjusters, noting their position on the pressure ring.
4. Lift the pressure ring assembly off the flywheel and set the flywheel and disc aside. To remove the levers, use a hammer and punch to remove the 3 plate pins from the lugs. The lever/yoke assembly will now lift out of the plate. Note the steel bushings in the plate pin holes of the lever.
5. Now we will reinstall the lever assemblies in the new pressure ring. Put a dab of
anti-sieze on the outside of the bushings and slip them back into the levers. Place the lever assembly into the pressure ring lug.
6. It is critical to re-install the plate pins with the cotter pin hole facing properly. If you are looking at the side of the lug, you want the top of the pin hole to be in the one o’ clock position, the bottom of the hole in the seven o’ clock position.
(Dia. A) This is important so the cover will properly clear the cotter pins when replaced. The plate pins are serrated so you must position them before driving them back into the lugs.
||Make sure the pin is inserted in
this manner so as to clear the cover when reassembled.
7. Install the new cotter pins in each plate pin with the head in the one 'o clock position. Bend the cotter pin ends back towards the inside of the clutch (one o’clock position).
8. With the pressure ring now preassembled, place it back on the flywheel and disc. Line up the plate lugs between the close pairs of flywheel studs.
9. Set the cover on the unit and check the ring height measurement. Adjust the shims on the flywheel as
necessary so that the ring height is correct. Remove the cover.
10. (If applicable) Check all the adjusters to make sure the screws are not binding. Take each screw out of the adjuster and lubricate with anti-seize. Reinstall the adjuster screws and turn them all the way in.
11. Place the springs back on the spring lugs of the pressure ring. (If applicable), set the adjusters back on top of the appropriate springs, making sure not to mix the springs from their original position. Set the cover back over the plate and onto the studs, making sure the springs and adjusters sit all the way up inside the spring cups of the cover.
12. Replace the cover nuts and draw the cover evenly back down to the flywheel. As the cover window reaches the plate lugs, make sure the lugs are inside the windows and not binding on the cover.
13. The next step is setting the lever heights. Be patient and take your time in order to get the levers as close as possible.
14. Measuring from the top of the cover to the lever tips sets the lever heights. Place a straight edge across the cover and measure down to the tips, subtracting the thickness of the straight edge. The proper
measurement is .745” from the top of the cover.
15. Yoke shims come in three thicknesses - .005", .010", and .025". The thickness of the shim will move the lever height on approximately a 3-1 ratio; a .025" shim will effect the lever height by about .075".
16. Place a small pin punch through the yoke bolt hole and into the yoke bolt hole. This will help you keep the yoke aligned as you install the shims. Slide a shim (.005", .010", or .025") in between the yoke and cover, lifting up on the punch to allow the shim in-between. Once it is in place, pull the lever back up to the cover and install the yoke bolt. Repeat this procedure on each lever, until the levers are within .015-.020" of the proper measurement.
17. Once the levers are even, they will need to be cycled a few times for them to 'set'. Use a 1/2 or 9/16 closed box end wrench to flex each lever up and down several times. Re-measure the lever heights from the cover.
18. Finally we are ready to fine tune the lever heights. If necessary, remove the yoke bolts one at a time and add or remove shims. Holding up the lever as you remove the bolt and slipping your pin punch into the hole will keep the shims you already installed from falling out.
19. Cycle the levers a final time and re-measure the lever heights. Ideally these should be within .015-.020" when completed.
20. Once everything is completed, remove the yoke bolts one last time, holding up on the levers, and apply a few drops of loctite to the threads. Re-install the bolts for the last time - you are now ready to go!