Clutch Disc and Pressure Plate, Remove and Install Notice: As of MY '92, the previous flat flywheel is being gradually replaced by a pot flywheel. Before clutch repairs, check whether a pot flywheel is installed in the affected vehicle by removing the closure cover. The transmission is to be removed for vehicles with 17 DT and all vehicles with pot flywheel and enclosed transmission housing - refer works instruction "Transmission Dismantling and Installation".
Vehicles with flat flywheel: manual transmission installed.
 Remove, Disconnect Retaining clamp (arrow) from cable. Press back clutch release lever with installing iron. Cable from clutch release lever. | 
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Remove, Disconnect Left front wheel, end shield cover, fluid escapes, clutch closure cover, retaining ring from drive shaft (arrow), fillister head bolt from drive shaft. | 
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Remove transmission drive shaft with KM-556-1-A and KM-556-4 up to stop from gear block and clutch disc. | 
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Press back release lever with installing iron and thus tension diaphragm spring of clutch pressure plate. Attach 3 clamps KM-526-A (arrow) distributed around circumference. | 
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Installed or removed transmission:
Remove, Disconnect Clutch pressure plate with clutch disc from flywheel, clutch pressure bearing from clutch fork, fastening bolt (arrow) of clutch fork. | 
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Remove, Disconnect Clutch release lever, clutch fork, pressure bearing guide (arrow), seal ring from pressure bearing guide. | 
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 Install, Connect Press new seal ring in thrust bearing guide and fill seal ring between sealing lips with molybdenum sulphide paste.
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Press in seal ring: |
F 10, F 13, F 15: |
KM-445 |
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F 16, F 18, F 18+ F 20: |
KM-518 |
O-ring in housing groove free of grease and fluid. | 
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 Tighten (Torque) Thrust bearing guide to transmission, 5 Nm/4 lbf. ft., coat sliding surface for clutch thrust bearing with grease. Clutch pressure bearing, clutch fork to clutch release lever, 35 Nm/26 lbf. ft. |
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Transmission installed: If clutch pressure plate is being replaced: Press diaphragm spring of clutch pressure plate on the clamp. Install 3 clamps KM-526-A distributed on circumference of new clutch pressure plate. | 
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Install, Connect Clutch pressure plate with clutch disc loosely at flywheel, coat splines of clutch disc with grease. If label "transmission side" is missing: Install with long part of clutch disc hub pointing towards transmission.
 Important! Marks on clutch pressure plate and flywheel (arrow) must match. | 
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Install, Connect Raise clutch disc and centre with transmission drive shaft. Insert drive shaft into clutch disc and gear cluster splines carefully by hand.
Tighten (Torque) Clutch assembly to flywheel, 15 Nm/11 lbf. ft. | 
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Fillister head bolt in drive shaft - 15 Nm/11 lbf. ft.
Install, Connect Press in drive shaft until stop, KM-564 - partially releasing the clutch at the release lever facilitates installation. Fillister head screw in drive shaft. | 
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Remove, Disconnect KM-564, KM-526-A (arrow) with clutch release lever actuated.
Tighten (Torque)
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Closing cover clutch to transmission: |
12 Nm/9 lbf. ft. |
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Sheet metal version, |
20 Nm/15 lbf. ft. |
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Light alloy version |
6 Nm/4 lbf. ft. |
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Transmission cover to transmission and end shield, |
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M7 x 1.0 |
15 Nm/11 lbf. ft. |
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M8 x 1.25 |
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Transmission removed: centre clutch disc
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Manual transmission |
F 10/F 13 |
F 16/F 18 |
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F 15 |
F 18+/F 20 |
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Engine |
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17 DT |
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KM-733 |
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Crankshaft with needle bearing |
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KM-534 |
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Crankshaft without Needle bearing |
KM-734 |
KM-735 |
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Install, Connect Clutch pressure plate to flywheel - tightening torque 15 Nm/11 lbf. ft.
Important! Marks on clutch pressure plate and flywheel must match.
Install, Connect Transmission - refer works instruction "Transmission Dismantling and Installation".
All transmissions:
 Inspect Transmission fluid level - see operation "Transmission Fluid Level, Check". | 
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Install, Connect Clutch cable to release lever retaining clamp (arrow).
 Adjust Clutch pedal See operation "Clutch Cable, Replace". |
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