Release bearing

11. Using a straight edge and feeler gauges check the surface of the pressure plate for flatness at 4 separate points. Renew clutch cover assembly if warping exceeds service limit. Pressure plate warping: Service limit = 0.20 mm maximum

Release bearing

12. Remove release bearing.
13. Remove ’E’ clip securing clutch release shaft. Discard ’E’ clip.
14. Withdraw shaft and remove fork.

NOTE: Shaft and fork have master splines.

15. Remove release shaft bushes.
16. Examine release bearing for signs of wear or damage, renew if necessary.
17. Check release fork, shaft and bushes for wear. Renew if necessary.

Refit

1. Clean clutch release fork and release bearing guide sleeve.
2. Clean clutch release shaft bush locations in clutch housing and fit bushes.
3. Smear release fork shaft and bore of release bearing with molybdenum disulphide grease.
4. Position release fork, align master spline and slide shaft through into position.
5. Fit NEW ’E’ clip.
6. Fit release bearing.
7. Operate release lever to ensure that release bearing is correctly located on release fork and slides smoothly on guide sleeve.
8. Clean pressure plate and flywheel, dowels and dowel holes.
9. Inspect flywheel for signs of scoring or other damage. Renew if worn or damaged.
10. Smear clutch drive plate splines with molybdenum disulphide grease.
11. Position drive plate to flywheel with ’FLYWHEEL SIDE’ marking towards flywheel.

12. Fit clutch cover to flywheel and fit alignment tool 18G 1617.
13. Fit 6 bolts securing clutch cover to flywheel finger tight.