Owners manual

CLUTCH INSTALLATION INSTRUCTIONS cont.
PILOT BEARING/BUSHING
When a vehicle is so equipped, the pilot must be replaced. The pilot is located in either the engine's crankshaft or in the center of the flywheel.
To remove a flywheel-fit pilot, remove the flywheel from the engine and drive or press out the pilot from the backside of the flywheel. Press or
gently tap new pilot into flywheel after flywheel has been machined (where applicable). For crankshaft-fit pilots, an effective means for removal
is to select a drift punch or wooden dowel that fits snugly into the old pilot. Then, pack the old pilot tightly with grease. Using the drift punch (or
dowel) and a hammer, drive the grease toward the engine. The grease will not compress and will In turn push the old pilot out of the crankshaft.
Install the new pilot carefully using a bearing driver.
NOTE: Do not grease new pilots. New pilot bearings come pre-greased (often with special synthetic grease). Bronze pilot bushings have oil in
the pores the material that grease will clog. For bushings, a few drops of SOW oil can be used if desired.
PRESSURE PLATE AND DISC
Install flywheel (refer to flywheel section above). Always tighten flywheel to crankshaft bolts in a star pattern to manufacturer's torque
specification. Before installing the disc, make sure that it slides smoothly on the transmission input shaft. DO NOT USE ANTI-SEIZE! It does not
cling to rotating parts. Slide the disc back and forth on the input shaft and remove any extra grease that squishes out of the splines of the disc.
Do not get grease or oil on the disc facing. Any grease or oil on a disc facing can be removed with alcohol or brake cleaner if done quickly. Lay
the disc on the flywheel noting the flywheel side of the disc and hold it in place with the alignment tool. Clean the pressure ring of the pressure
plate with brake cleaner to remove the rust inhibiting coating. Do not spray the entire pressure plate with brake cleaner as lube for internal parts
will be removed. Set the pressure plate on the flywheel dowel pins (if equipped) and hand tighten the hold-down bolts. With hand tools, tighten
pressure plate bolts Vs turn at a time in a star pattern until they have reached manufacturer's torque specifications for OEM flywheels or 35 ft.
Ibs. for aluminum flywheels. Remove the alignment tool.
NOTE: Different brands of the same pressure plate may have a difference in appearance and uninstalled lever height. These are not issues.
Appearance can vary greatly and the installed lever height will be the same.
RELEASE BEARING (fork mounted)
Lightly grease all contact points of the fork, pivot ball and release bearing. Assemble noting the proper position of any clips or retainers. If the
be!l housing separates from the transmission, it is helpful to install the bell housing and the linkage to check for proper clutch release before the
transmission is installed. Do not attempt to start the vehicle when doing this.
RELEASE BEARING (concentric slave cylinder)
A concentric slave cylinder assembly takes the place of a fork, pivot(s), linkage, conventional release bearing, and the quill of the transmission
input shaft bearing retainer. Slide assembly over input shaft and torque fasteners to specification.
VEHICLE REASSEMBLY
Make sure alignment dowel pins are secured in the back of the engine block. Make sure engine and transmission mating surfaces are clean and
free from burrs. Put the transmission in gear. Using a transmission jack, lift transmission into position. Carefully mate the transmission to the
engine and bolt together. If the transmission will not easily mate up to the engine, slip the driveshaft onto the transmission output shaft (RWD)
or partially insert CV shaft into differential (FWD) and turn slightly to align the input shaft splines with the disc. It may also be necessary to
adjust the transmission angle. Do not force the transmission into place. This will likely damage the disc.
NEVER USE BOLTS TO DRAW THE ENGINE AND TRANSMISSION TOGETHER
Make sure no engine or transmission sensors, wiring harnesses, or hoses come between the engine and transmission. This will cause
misalignment, and ultimately clutch failure. Reverse removal procedure for assembling the rest of the vehicle. Properly torque all fasteners.
Check transmission (transaxle) fluid level and add the recommended fluid as necessary. On 4WD/AWD vehicles, check transfer case fluid level
and add the recommended fluid as necessary.
NOTE: On vehicles with a manually adjustable cable or rod and bell crank release linkage, adjust to move the release bearing to within
approximately 3/8 of the pressure plate levers (fine adjustment may be necessary to get clutch to engage at the desired pedal travel). On
vehicles with a self adjusting cable it may be necessary to cycle the clutch pedal several times and/or pull up on the clutch pedal to make the
clutch work properly. On vehicles with a hydraulic release mechanism, it is good practice to bleed the system.
NOTE: On RWD and 4WD vehicles, align the mark(s) on the driveshaft(s) with those made on the yoke(s) during disassembly to prevent
possible driveline vibration and clutch chatter during engagement.
TEST DRIVE
Make sure clutch engages smoothly within the desired pedal travel. Make sure there are no unusual noises. Drive until vehicle reaches normal
operating temperature cycling through all gears. Some burnt clutch smell is normal on the initial test drive. When practical, allow vehicle to cool
down and drive a second time. The clutch should be burnished in and ready for a torque capacity field test. Drive up hill in the highest gear the
engine will allow without bogging down and fully depress the accelerator. This puts maximum strain on the clutch and would reveal any problem
with its holding power. Watch the tachometer to check for clutch slippage.
NOTE: Never perform a live clutch test (engine running) with the wheels of the vehicle off of the ground. The backlash effect of the unloaded
driveline could bend the drive straps of the pressure plate causing poor or no release and/or chatter upon engagement.
Tech Line 1-440-259-5656
www.fidanza.com
2 VER. 04.13 (#600013)