A clutch centre holding tool can easily be made using two strips of steel bent over at the ends and bolted together in the middle

Engine, clutch and transmission 2»27

16.9 Grasp the pressure plate and clutch centre and draw the assembly off

8 Unscrew the clutch nut and remove the Belleville washer from the shaft, noting which way round it fits. On R models, also remove the thrust washer, again noting which way round it fits. Discard the nut as a new one must be used.

9 Grasp the clutch centre with the complete set of clutch plates and the pressure plate and remove them as a pack (see illustration). Unless the plates are being renewed, keep them in their original order. Note that of the friction plates, there are two types, the outermost plate having a larger internal diameter to the other friction plates. This is to accommodate the anti-judder spring and spring seat that fit between the outer friction plate and the clutch centre. On J and К models, the outermost plain plate is also slightly different. Take care not to mix them up.

10 On L, N and R models, remove the thrust plate from the input shaft, not ng which way round it fits (see illustration 16.27).

11 Remove the clutch housing (see illustration).

12 If required, withdraw the clutch housing bush from the centre of the oil pump drive sprocket to provide slack in the chain, then slip the chain off the driven sprocket and remove the drive sprocket and chain, and the thrust washer (see illustrations 16.24 and 16.23b and a). Note the pins on the drive sprocket which locate in the holes in the back of the housing.

Draw the housing off the shaft

Inspection

13 After an extended period of service the clutch friction plates will wear and promote clutch slip. Measure the thickness of each plate using a vernier caliper (see illustration). If the thickness is less than the service limit given in the Specifications at the beginning of the Chapter, the friction plates must be renewed as a set. Also, if any of the plates smell burnt or are glazed, they must be renewed.

14 The plain plates should not show any signs of excess heating (bluing). Check for warpage using a surface plate and feeler gauges (see illustration). If any plate appears warped, or shows signs of bluing, all plain plates must be renewed as a set.

15 Measure the free length of each clutch spring (see illustration). If any spring is below the service limit specified, renew all the springs as a set.

16 Inspect the clutch assembly for burrs and indentations on the edges of the protruding tangs of the friction plates and/or slots in the edge of the housing with which they engage. Similarly check for wear between the inner tongues of the plain plates and the slots in the clutch centre. Wear of this nature will cause clutch drag and slow disengagement during gear changes, since the plates will snag when the pressure plate is lifted. With care, a small amount of wear can be corrected by dressing with a fine file, but if this is excessive the worn components should be renewed.

16.13 Measuring clutch friction plate thickness

17 Check the release plate, release bearing, and pushrod for signs of roughness, wear or damage, and renew any parts as necessary. Check that the bea'ing outer race is a tight fit in the centre of the plate, and that the inner race rotates freely without any rough spots.

18 Measure the clutch housing bush inner and outer diameters, and the diameter of the input shaft where tae bush fits. Compare the measurements to the specifications at the beginning of the Chapter and renew the bush and/or the shaft if they are worn beyond their service limits. Also check all the above components, and the needle bearing the clutch housing, for signs of damage or scoring, and renew if necessary.

19 Check the pressure plate, and on L, N and R models the thrust plate for signs of roughness, wear or damage, and renew any parts as necessary.

20 Check the anti-judder spring and spring seat for distortion, wear or damage, and renew them if necessary.

21 Check that the release shaft rotates smoothly in the clutch clover. If the action is rough or stiff, free the spring end from the spring pin in the shaft and draw the shaft out of the cover (see illustration). Check the condition of the two needle bearings - the action may be improved by cleaning them with solvent and applying some oil, but otherwise they should be renewed. Also renew the oil seal if it is damaged or deteriorated, or shows any signs of leakage.

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