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VIN Info - What Model Do I Have
Large Frame Clutch Rebuild
Torch
Hammer (rubber and regular)
Clutch Tool
T-20322
Flat Head Screwdriver
Chisel
Pick
Channel Locks
Small Block of wood
Vice (not nessasary)
Insert the screw part of clutch tool into back of the clutch (side with the gear)
Flip the clutch over and insert the ring part
Put the nut part into the vice (if you are using one)
if not just put the nut on
Screw it into the nut
You can tighten it simply by spinning the whole clutch clockwise
Once it is full compressed use a small flat head screwdriver to pry off the
Circlip
Continue working it around
Pull it off
The top plate may be difficult to remove if so use a screwdriver to pry it off
Once to top plate of off you can grab the gear and remove all the rest of the plates
Inspect the
cork plates
REPLACE them
Inspect the
metal plates
they should not be shiney if so REPLACE
This is no goood they should not be black or burnt most likely if you are rebuilding the clutch these are the problem ALWAYS REPLACE
Inspect the
Drive Gear
it should have no play whatsoever (hold the plate still and try to move the gear (it should be tight)
If it is loose simply use a ball peen hammer and smash the rivets flat.
Inspect the
Brass Bushing
if it is loose or scored in anyway REPLACE it.
Next loosen the clutch for the tool by spinning it counter clockwise
Pull the tool out
Pull the Backplate off
Six Spring
159905
Seven Spring P200
159853
ALWAYS replace the
Springs
Remove the
Brass Washer
To remove the Bushing (if it doesn't just pull off with your fingers) Hit it with a chisel one swift hit should do it. Don't hit it too hard you don't want to damage the backplate.
Remove the
Springs
Remove the
Cups
Inspect the Clutch Basket check for cracks REPLACE if necessary.
Time for Reassembly
Put the Heat on the
Brass Bushing
NOT TOO MUCH just hold the flame on for a few seconds don't discolor it.
Use your channel locks to pick it up IT'S HOT!!
Place it on the Back Plate
Six Spring
159905
Seven Spring P200
159853
Get the
Brass Bushing
started with the rubber end of you hammer
If you have a vice place your block of wood on the bushing side and slowly close the vice.
If you don't have a vice you can use the old bushing to hammer the new one on.
Remember SLOWLY if you go to fast you can crack the bushing
Put your Clutch Tool
T-20322
nut back into the
Put the basket on the ring part of the tool
Replace the
Cups
Replace the
Springs
Replace the Back Plate
Six Spring
159905
Seven Spring P200
159853
Make sure on the P200 you align the hole in the back plate with the hole in the basket
Insert the Screw part of the tool
Again spin the clutch clockwise to compress the
Springs
. Only compress them about half way
Using a small pick of screwdriver push the tops of the
Springs
until they make a CLICK sound.
THIS IS VERY IMPORTANT YOUR CLUTCH WON'T WORK PROPERLY IF YOU SKIP THIS STEP!!
This is what you are doing (CLICKING the springs into the recesses on the Back Plate
Six Spring
159905
Seven Spring P200
159853
Compress the springs all the way now.
Install the
Brass Washer
Oil the
Brass Bushing
with SAE30 oil
Install the
Drive Gear
making sure it spins freely
Install the OIL SOAKED
cork plate
Install the
metal plate
Another
cork plate
Another
metal plate
Finally the last
cork plate
will go on cork side down
Install the
circlip
by holding it in place with you finger and working it into the groove with the other.
When you are done the break in the
Circlip
should be on a solid part of the Basket
There you have it, now that wasn't so bad was it