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One Alto Way
Atmore, AL 36504

EMAIL:
sales@altousa.com

PHONE:
251.368.7777

FAX:
251.368.7774

Reinstallation of New Clutch Kit

Once you are ready to reinstall the new clutch kit, the important issue becomes cleanliness. Greasy hands can easily contaminate a clutch disc. Grease on the disc will cause clutch chatter. If this should happen the best cleaner to use is acetone. It does not leave a residue on the product.

Install pilot bearing/bushing. It is best not to lubricate the pilot bearing or bushing. Both types of pilots are pre-lubricated. If the pilot bushing is lubricated with grease it will fuse itself on the end of the input shaft and at that point the clutch system in inoperable. It should be pointed out that the only time the input shaft of the transmission is rotating in the pilot is when the clutch pedal is depressed all the way. When installing the pilot in the end of the crankshaft, place a flat non-metallic material between the pilot and the installation tool. As you tap the pilot into the end of the crank be sure that it is going evenly. The pilot bearing/bushing must be flush with the end of the crankshaft.

Installing a resurfaced flywheel. Inspect both the flange on the crankshaft and the mounting surface of the flywheel. Make sure there are no burrs that might prevent the flywheel and the crankshaft flange from mating evenly. On older vehicles, which have had the clutch system replaced more than once, it is possible that the flywheel may be too thin. The problem with this condition is the possibility of the flywheel bolts coming in contact with the clutch disc hub. To check this, hold the flywheel flat and drop the flywheel mounting bolts through the holes of the flywheel. Lay a straight edge across the flywheel surface over the bolts. If the straight edge does not touch the bolt heads, there will be no interference. When installing the flywheel, Do not use air impact tools. Place some thread lock adhesive on the bolts and start them by hand. Tighten the flywheel bolts in a star pattern using three passes. Once the bolts are tight, torque them to the vehicle manufacturer’s specifications. Be sure to wipe off the contact surface of the flywheel with acetone to remove any grease or coating.

Install the clutch disc and cover. Before placing disc on the flywheel, place the disc on the input shaft of the transmission and slide back and forth to ensure fit. Put a thin coating of white lithium grease on the splines. Place the disc against the flywheel with the flywheel side of the disc against the flywheel. Place the disc alignment tool through the disc splines, and press it firmly into the pilot bearing/bushing. This should hold the disc while you place the cover assembly over the disc. Before placing the cover against the disc, wipe the pressure plate surface with acetone to remove any grease or coating that may be present. Place the cover against the clutch disc, and insert the bolts by hand. Insert all of the bolts and then begin to tighten in a star pattern by hand. Do not use air impact tools. Once the bolts are tight, torque them to the vehicle manufacturer’s specification. Remove the alignment tool.

Install the clutch release bearing. Inspect the new clutch release bearing and be sure there is grease inside the I.D. of the bearing. Most of the bearing manufacturers pre-lubricate their bearings, but there are a few exceptions. This grease allows the bearing to slide easily on the transmission quill. Attach the clutch release bearing to the clutch fork. Apply a thin layer of white lithium grease on the ball stud. Install the fork assembly on the ball stub in the bellhousing. Inspect the clutch fork mechanism for smooth operation. Before reinstalling the bell housing, inspect the mounting surface of the bellhousing. Make sure it is clean and smooth. If there are any burrs use a wire brush to remove. The bellhousing must be perfectly flat against the engine, or a possible misalignment of engine and transmission will occur. Install the bellhousing by placing all of the mounting bolts in by hand and tighten using a star pattern with three passes. Do not use air impact tools.

Install the transmission. A transmission jack is recommended to hoist the transmission in position. The transmission needs to be supported completely to avoid hanging the transmission on the clutch disc. In many cases the clutch job is ruined at this point. The transmission is allowed to hang on the clutch disc before the input shaft is in place in the pilot bearing, the result is, the clutch hub becomes bent and will now wobble on the input shaft. This will prevent a release. If a transmission jack is not available, install long guide pins in the top mounting boltholes of the bellhousing. Place the transmission on the guide pins and slide forward. These will support the transmission while you install the lower mounting bolts into the bellhousing. As you slide the transmission forward, do so slowly. Be sure the input shaft of the transmission slides easily through the I.D. of the clutch release bearing and that you do not knock the fork off of the ball stud. Install the mounting bolts of the transmission and tighten using the star pattern with three passes.