Clutch Disc: Service and Repair

1. Disconnect battery ground cable, raise and support vehicle, then remove transmission and clutch housing dust cover.
2. On models with DME-Motronics system, note installation position of speed and reference mark transmitters, then remove transmitters from clutch housing. Speed transmitter (black electrical connector) is installed facing ring gear, while reference transmitter (connector with gray ring) is installed facing flywheel reference pin. If sensors are not properly installed, engine will not start.
3. Remove clutch housing and measure height of pressure plate fingers. If deviation is greater than .024 inch, pressure plate should be replaced.
4. Lock flywheel with holder 11 2 160 or equivalent. Remove pressure plate bolts 1 to 1-1/2 turns at a time until tension is released.
5. Remove bolts, pressure plate, and clutch disc.
6. Check clutch disc for wear or cracks. Make sure torsional damper springs are tight and check lateral runout.
7. Inspect needle pilot bearing in crankshaft and check flywheel for cracks.
8. Inspect pressure plate for cracks, loose rivets, wear, and burnt spots. Check flatness of pressure surface.
9. Reverse procedure to install. Align clutch disc with tool 21 2 100 or equivalent. Apply suitable grease to transmission input shaft splines. Torque pressure plate bolts to 16-17 ft.lbs. (22-24 N-m).