Clutch Release Components
1 - Shutdown lever; 2 - Spring anchor; 3 - Spring; 4 - bushing of the shutdown lever; 5 - Fork of the clutch release lever; 6 - Retaining ring; 7 - Screw; 8 - Release bearing; 9 - Pin 4x10; 10 - Screw; 11 - Guide pin of the release bearing; 12 - O-ring
Note. See the warning at the beginning of Section Removing, checking the condition and installing the clutch assembly.
Removing
1. If the power package is not removed from the vehicle and not dismembered, access to the components of the clutch release mechanism can be provided by dismantling the transmission. The components of the shutdown mechanism are shown in the illustration.
2. Turn out a bolt of fastening of a turn-off plug on an axis of the turn-off lever, remove a washer.
3. Disconnect the spring from the top of the axle and remove the lever from the gearbox housing. Remove fork assembly with release bearing (try to remember its installation position), then divide into two parts (fork and bearing).
Examination
4.Check the condition of the clutch release mechanism components. Replace defective or worn parts. Carefully inspect all contact and support surfaces.
5. It is good practice to replace the release bearing regardless of its condition. In case of tight financial circumstances, check the freedom of rotation of the bearing and the condition of its contact surface. If defects are found, the bearing must be replaced.
6. Worn bushing of the axle of the clutch release lever must be replaced. The old bushing is knocked out of its seat with a hammer and punch. To fit a new bushing, use a replacement head of the appropriate size or a piece of pipe of a suitable diameter as a mandrel (the mandrel should rest only on the outer edge of the end surface of the sleeve).
Installation
1. Thoroughly clean all components, completely removing all traces of old sealant from the clutch release fork and the threaded part of its bolt. Make sure that the release lever axle bushing is properly seated in the gearbox housing.
2. Apply a thin film of high temperature grease such as Kluber Microlube GL202, GL261 or GL262 or Mobil lithium 932 or 933 to the contact surfaces of the lever shaft, release fork and release bearing. Try not to let grease get on the friction linings of the clutch disc.
3. Connect the release fork to the release bearing.
4. Slide the yoke/bearing assembly onto the transmission guide sleeve, then slide the linkage assembly into the yoke.
5. Lightly coat the threaded portion of the fork retaining screw with a suitable sealant (sealant such as Tree bond or Aldrit is best). Align the yoke and arm axle, then carefully screw in the bolt. After making sure that the bolt fits correctly in the holes, tighten it with the required force.
6. Connect the spring to the top of the release lever. Before installing the gearbox on the engine, make sure that the clutch release mechanism is working properly.