Clutch problems - various

CLUTCH PROBLEMS - VARIOUS

Model

New 220, New 420, 620, 820, 220/420, 218/418, Maestro 2.0, Montego 1.6/2.0

Affected vehicles

All vehicles with PG1 gearbox

Reference

R1225bu

Bulletin text

New 220, New 420, 620, 820, 220/420, 218/418, Maestro 2.0, Montego 1.6/2.0

AFFECTED RANGE:

All vehicles with PG1 gearbox

PROBLEM:

CLUTCH PROBLEMS - VARIOUS

Any clutch fault requiring clutch replacement and particularly clutch judder.

CAUSE:

Conventional clutch assembly procedure can result in cover distortion or uneven pressure plate lift, thus causing various clutch conditions.

ACTION:

Use of the following procedure and special tool allows the clutch cover to be fitted in the disengaged condition thus preventing distortion of the cover during tightening;

If symptom was ‘clutch judder’ ensure initial cause was not oil leaks, if oil contamination is found investigate source, i.e. possibly from input seal or right hand drive shaft seal, rectify as required.

If symptom was ‘difficult engagement of reverse’ first refer to Technical Bulletin 0002 - transmission section then refer back to this bulletin for reassembly procedure.

If symptom was ‘jerky/stiff clutch pedal’ first refer to Technical Bulletin 0013 -transmission section then refer back to this bulletin for re-assembly procedure.

A new clutch aligning tool ‘18G1767’ has been issued to all UK dealers and ordering information advised to international distributors. This new tool supersedes previous tool 18G1483.

Bull. N o : 0020

1 12/02/97

Procedure for use of 18G1767 clutch aligning tool

• • Ensure flywheel dowels are fully home.

• • Loosely assemble clutch plate and cover onto flywheel dowels. Fit but do not tighten cover bolts.

• • Unwind bolt on tool until 60mm dia. flange touches the body of the clutch tool.

• • Using bolts and nuts from engine/gearbox assembly secure clutch tool to backplate (in position shown on illustration).

• • Wind bolt onto clutch cover fingers, making sure the driven plate bore is picked up.

• • Compress clutch cover fingers by winding in the bolt, check the driven plate for rotation before the stop nut reaches the body of the clutch tool.

• • When the driven plate is in the released condition tighten clutch cover bolts, using standard locking procedure.

• • Unwind the bolt to release the clutch cover fingers.

• • Remove nuts and bolts, then remove clutch tool from dowels

• • Unwind bolt until the 60mm dia. flange touches the body of the clutch tool.

PARTS INFORMATION:

18G1767...........Clutch Aligning Tool Note: Aligning tool has been supplied to all dealers as a tool board item. Refer to parts fiche for clutch replacement parts

WARRANTY CLAIMS: Not applicable, this bulletin has been issued to advise the general use of new clutch aligning tool 18G1767.