Manual - Chapter 2 Clutch

4. Examination and renovation

  1. If the clutch friction plate is damaged in any way, or if the friction material is worn to the rivets, fouled with grease or oil, or glazed, it must be renewed as a matter of course. If it appears to be in good condition measure the thickness of the friction material at several points; if the plate is worn to 4.5 mm (0.1772 in) or less at any point, it must be renewed.
  2. Check carefully the condition of the friction plate centre splines and check for signs of cracking or splitting around the centre; if any damage is found the plate must be renewed.
  3. Check the friction and pressure plates for distortion and the spring pressure of the diaphragm spring; renew any component that is found to be damaged, worn or otherwise faulty.
  4. If the clutch action has become sudden, with grabbing or snatching in evidence, first check the release mechanism (see Section 6). If this is in good condition check closely the gearbox input shaft and friction plate centre splines; renew either component if excessive wear is found. Lastly check the preload of the input shaft. See Chapter 3 - Gearbox.
  5. If the clutch has been slipping and the plate friction material is found to be in good condition, the clutch cover plate should be checked very carefully and renewed.
  6. If oil has found its way into the clutch housing, thoroughly degrease ail clutch components and wash all traces of oil off the crankcase and gearbox castings. Check the seals at the output shaft rear end and the gearbox input shaft front and rear. Check carefully that the housing has not been rubbing on the output shaft seal, renewing the seal if traces of this are found.
  7. Note that the clutch housing retaining nut is of the self-locking type and must be renewed whenever it is disturbed; also the housing O-ring.
  8. If severe damage to clutch components or excessive wear of the splines is found, check that the locating dowels are fitted to align correctly the engine, bell housing and gearbox castings. There are two large locating dowels set in each of the bell housing front and rear faces; always ensure that these are refitted whenever the bell housing joints are disturbed.

Next Section: 5: Reassembly

4.1 Measuring clutch friction plate thickness