The last area to check before reassembly is the
clutch fork. If it is bent or worn, the fork can prevent
the clutch from releasing properly. Inspect both ends
of the fork closely. Also, inspect the clutch fork pivot
point in the clutch housing; the pivot ball or bracket
should be undamaged and tight.
When a new pressure plate is installed, do not
forget to check the plate for proper adjustments. These
adjustments will ensure proper operation of the
pressure plate. The first adjustment ensures proper
movement of the pressure plate in relation to the cover.
With the use of a straightedge and a scale as shown in
figure 4-11, begin turning the adjusting screws until
you obtain the proper clearance between the
straight-edge and the plate as shown. For exact
measurements, refer to the manufacturers service
The second adjustment positions the release levers
and allows the release bearing to contact the levers
simultaneously while maintaining adequate clearance
of the levers and disc or pressure plate cover. This
adjustment is known as finger height. To adjust the
pressure plate, place the assembly on a flat surface and
measure the height of the levers, as shown in figure
4-12. Adjust it by loosening the locknut and turning.
After the proper height has been set, make sure the
locknuts are locked and staked with a punch to keep
them from coming loose during operations. Exact
release lever height can be found in the manufacturers
Reassemble the clutch in the reverse order of
disassembly. Mount the clutch disc and pressure plate
on the flywheel. Make sure the disc is facing in the
right direction. Usually, the disc's offset center (hub
and torsion springs) fit into the pressure plate.
Figure 4-12.Pressure plate release lever adjustment.
If reinstalling, the old pressure plate lines up the
alignment marks made before disassembly. Start all of
the pressure plates bolts by hand. Never replace a
clutch pressure plate bolt with a weaker bolt. Always
install the special case-hardened bolt recommended by
Use a clutch alignment tool to center the clutch
disc on the flywheel. If an alignment tool is
unavailable, an old clutch shaft from the same type of
vehicle may be used. Tighten each pressure plate bolt a
little at a time in a crisscross pattern. This will apply
equal pressure on each bolt, as the pressure plate
spring(s) are compressed. When the bolts are snugly in
place, torque them to the manufacturers specifications
found in the service manual. Once the pressure plates
bolts are torqued to specs, slide out the alignment tool.
Without the clutch disc being centered, it is almost
impossible to install the transmission or transaxle.
Next install the clutch fork and release bearing in
the clutch housing. Fit the clutch housing over the rear
of the engine. Dowels are provided to align the housing
on the engine. Install and tighten the bolts in a
Install the transmission and drive shaft or the
transaxle and axle shafts. Reconnect the linkages, the
cables, any wiring, the battery, and any other parts
required for disassembly. After all parts have been
installed, adjust the clutch pedal free travel as
prescribed by the manufacturer and test-drive the
vehicle for proper operation.
REVIEW 1 QUESTIONS
Figure 4-11.Pressure plate adjustment.
What is the function of the automotive clutch?