1. CHECK FLYWHEEL BORE In many cases the replacement of the clutch may have been downsized inadvertently.
2. FLYWHEEL RESURFACING A flywheel resurfaced 80 to 90 thousandths will make it difficult to obtain proper brake squeeze of 1/2” to 1” at the clutch pedal. TO AVOID FURTHER PROBLEMS: Replace the flywheel OR add one fiber brake washer (1/8” thick) on input shaft ahead of the normal Brake Washer being used. This will compensate for the flywheel wear. CAUTION: Check OEM specs as not to exceed minimum thickness allowed. 3. CHECK RETURN SPRINGS Check all four (4) return springs on the clutch assembly to assure that they are not bent, stretched or broken from handling or shipping. Grease the Throw-out bearing housing. 4. INPUT SHAFT Check the input shaft for excessive wear and looseness. Repair as needed. 5. CROSS SHAFT AND CROSS SHAFT BUSHING Check the cross shaft and the cross shaft bushing. Replace worn release forks. Worn parts will cause poor release or no-release. Problems that will arise not replacing worn parts: Over stroking the clutch to obtain proper brake squeeze of 1/2” to 1”. Throw-out fork will hit the top of the cover assembly thus causing further damage. 6. INTERMEDIATE PLATE Always check the intermediate plate BEFORE installation. 14” Pull Type: Must slide freely on the six (6) drive lugs. Do not tap or force in the flywheel. Misaligned or cocked drive lugs can result in a non-release condition. Correct alignment of drive lugs until the proper fit is achieved. 15-1/2” Pull Type: Test intermediate plate in the cover assembly. It must slide freely. Do not force it in. IF needed, deburr or polish areas that might have caused interference through handling or shipping. Tight fitting intermediate plates will not release properly. If this problem can not be resolved in the 14 and 15-1/2 units BEFORE installation, DO NOT CONTINUE TO INSTALL. Correct problem or replace the clutch. 7. CHECK CLUTCH DISCS Check both clutch discs so they travel freely on the input shaft, and make sure that each disc is correctly positioned in the installation. Failure to follow this step will cause severe damage to the discs and non-release problems with the clutch. 8. MOUNTING CLUTCH ASSEMBLY When mounting the clutch assembly to the flywheel, always use crisscross pattern and tighten evenly. Torque to pressure specifications. 14” Units Cover Assembly to Flywheel Capscrew 25-35 Ft-Lbs. 15-1/2” Units Cover Assembly to Flywheel Capscrew 40-50 Ft-Lbs. DO NOT tighten all of one side with an impact wrench as this will break or damage the unit. Check to insure that the clutch is seated properly in the flywheel lip. 9. INSTALLATION OF TRANSMISSION Good alignment or positioning of the input shaft is important. The transmission must slide in without obstruction. Raising or lowering or side movement of the jack after the input has passed through the clutch discs will bend or distort the clutch discs and possibly cause damage to the clutch cover assembly. Adjusting the internal adjusting ring will not compensate for bent discs. If damage is incurred during installation STOP Return damaged unit to your supplier for manufacturer’s inspection. 10. ADJUSTMENT Adjust 1/2” to 9/16 clearance between the transmission and the brake and bearing housing using external linkage. Adjust 1/8” between throw-out fork (yoke) and the bearing housinwith external linkage. THIS UNIT IS PRESET AND TESTED. Using internal adjustment will change the release factor; unit may slip or have a non-release factor.
