Section E (24/12/08
E.2 Clutch adjustments
E.3 Pedal adjustments
E.4 The clutch operating cylinder
E.5 The clutch master cylinder
E.6 The pedal assembly
E.7 Overhauling the clutch and release mechanism
E.8 The clutch release bearing
E.9 The clutch pilot bearing
E.10 Specifications and repair data
The clutch assemblies are of the single dry plate type
8,5 in. (215,9 mm) diameter.
The clutch disc incorporates a spring-cushioned hub;
the woven asbestos linings are flexibly mounted to ensure a smooth take-up
of the drive. The clutch disc hub is free to slide along the splines of
the main drive gear, the forward end of which forms a spigot to fit into
the clutch pilot bearing in the centre of the flywheel. The clutch cover,
springs, clutch release mechanism and pressure plate are serviced as an
At the release finger pivot points there is only
rolling contact, sliding friction is eliminated.
The clutch release mechanism is hydraulically actuated
by means of a pendant pedal mounted beneath the instrument panel,
controlling the clutch master cylinder. A pipeline and flexible hose
connects the master cylinder to the operating
cylinder mounted on the clutch housing and retained by means of a circlip.
Any possibility of irregular clutch engagement caused by movement of the
engine, clutch and gearbox unit in relation to the clutch pedal is
The clutch fluid reservoir is integral with the clutch
master cylinder and the level should be checked every 1,000 miles. Top-up with genuine brake fluid to the level
marked on the outside of the reservoir casing (see Fig. E.3), which is
approximately 1 in. (16 mm.) from the top. The cap and reservoir should be
wiped with a clean rag before removing the cap to ensure that no dirt or
foreign matter enters the system. Make sure that the vent is clear before
replacing cap. The only other attentions which may be required by the
clutch mechanism are the adjustments described as follows:
When the clutch mechanism is correctly adjusted the
following conditions apply:
Just perceptible clearance between the pedal push rod and master
1/16 in. (1,6 mm.) clearance between the clutch release arm and the
operating cylinder push rod.
The pedal returns to its stop without hesitation.
The adjustments can all be quickly checked at the clutch pedal. Very
slight movement of the pedal should be sufficient to take up the initial
clearance between push rod and master cylinder piston. If the clearance at
the operating cylinder is correct there will be approximately 1 in. (25,4
mm.) free travel before the clutch begins to be released. Full
instructions concerning the adjustment procedure appear hereafter.
The pendant clutch pedal is linked to the master
cylinder piston with an adjustable push-rod, with clevis attachment to the
The push-rod has an adjustment nut with lock nut and
these are positioned and locked together to correct pedal travel, as
necessary. The pedal pad is also adjustable, at its mounting point at the
foot of the pedal shank.
The clearance between the clutch release arm and
operating cylinder push rod should normally be 1/16 in. (1,6 mm.), although on a new car or after a new clutch disc has been fitted, the
clearance should be increased to 1/10 in. (2,7 mm.). Should
the clearance at this point be reduced, it is possible for the clutch
release bearing to be in permanent contact with the clutch-fingers,
causing unnecessary wear and possibly clutch slip.
To effect the adjustment, disconnect the retracting
spring, slacken the lock nut and turn the domed adjusting nut until the
correct clearance is obtained between the end of the release arm and the
nut. Tighten the lock nut securely, recheck the adjustment and reconnect
the retracting spring.
THE CLUTCH OPERATING CYLINDER
The clutch operating cylinder is mounted in the flange
of the clutch housing on the right-hand side and is held in place by a
Disconnect the retracting spring.
Using a pair of circlip pliers, remove the retaining circlip.
Withdraw the cylinder assembly forwards complete with push rod.
Remove the push rod and the dust excluding rubber cap. Gently
depress the clutch pedal to push the piston and seal out of the cylinder.
Disconnect the flexible hose and fit a blanking plug to the hose to
prevent fluid loss.
it be necessary to remove the cylinder complete without dismantling it as
described, a pump applied at the fluid union can be used to push the
piston and piston seal from the cylinder.
Remove the bleed valve from the cylinder.
Pull the rubber piston seal off the spigot at the front of the
parts in the correct hydraulic fluid,
methylated spirits or commercial alcohol and examine the rubber piston
seal carefully. Renew the seal if there is any sign
of damage to the sealing lip. Never use mineral
fluids such as engine oil or paraffin for washing hydraulic system parts.
Locate the piston seal on the spigot at the front end of the piston
so that the sealing lip is away from the body of the piston.
Dip the piston and seal in hydraulic fluid and carefully insert,
spigot end first, into the cylinder.
Refit the rubber cover over the end of the cylinder.
Replace the bleed valve in the upper of the two unions but do not
Remove the blanking plug from the end of the flexible hose and
reconnect the hose to the cylinder.
Replace the push rod and slide the cylinder into its location on
the clutch housing flange from the front. Replace the circlip and ensure
that it locates correctly in its groove.
Bleed the hydraulic system as described on page M.6.
Adjust the clearance between the domed nut on the operating
cylinder push rod and the clutch release arm as described previously.
THE CLUTCH MASTER CYLINDER
The clutch master cylinder is mounted on the engine
bulkhead and is bolted to the front flange of the pedal assembly bracket.
The front spigot end of the piston accommodates the
valve stem and carries the return spring retainer. The return spring
(under compression) is fitted between the spring retainer and valve spacer
at the forward end of the cylinder (see Fig. E.3). A valve seal is fitted
to the forward end of the valve stem. From approximate engine Nos.
204E-140540 and 206E-132253, an improved type of seal incorporating an
annular ring moulded on its outside periphery is fitted.
This modified seal should be fitted in place of the
previous plain seal if a replacement is required in service.
A reservoir port drilled at the front of the cylinder
allows fluid from the integral reservoir to enter the cylinder. The pipe
line to the clutch operating cylinder leaves the master cylinder at a port
immediately behind the reservoir. When the clutch pedal is in the fully
released position, fluid is free to flow from the reservoir into the
cylinder. When the pedal is depressed the piston moves forward and closes
the valve to prevent the fluid being pumped back into the reservoir. The
fluid is therefore pumped through the outlet port to the operating
cylinder on the clutch housing. When the pedal is once again released the
return spring pushes back the piston, reducing pressure in the cylinder,
and the release arm retracting spring acting on the operating cylinder
piston pushes the fluid back into the master cylinder. The valve uncovers
the reservoir port so that fluid may be replenisbed in the cylinder as
A rubber cap fits over the end of the master
cylinder and fits closely around the push rod to prevent the entry of dirt
into the cylinder.
clearance between the push rod and the piston on the cylinder is pre-set
and the piston cannot be prevented by the push rod from returning to its
THE PEDAL ASSEMBLY
The clutch pedal is of the pendant type, secured at its
top by a pivot bolt and connected to the master cylinder with an adjustable
Remove the clevis pin which connects the push rod clevis to the
Release loading spring.
Remove the top pedal pivot bolt and anti-rattle spring.
The assembly may now be manoeuvred downwards, and freed. Reverse this
procedure to refit, taking care to replace the anti-rattle spring.
To Remove the Master Cylinder
Remove the clutch shank clevis pin from the push-rod.
Disconnect the hydraulic pipe union from the cylinder body.
Remove the two bolts securing the cylinder body to the rear engine
Remove cylinder complete with push rod, and drain. Reverse procedure
to refit, taking care to re-set the pedal adjustment to give 'just
perceptible' movement before engaging the master cylinder piston stroke.
OVERHAULING THE CLUTCH AND RELEASE
To gain access to the clutch, the gearbox or engine
must first be removed.
remove the clutch disc and pressure plate assembly, slacken the six securing
screws evenly and detach the assembly. Inspect the clutch disc and check
that the linings are not loose and are free from oil. The discs should also
be checked for excessive wear or signs of overheating. Replace the disc if
the linings are worn down near to the rivet heads, or if any of these
conditions are apparent. Check the condition of the surface of the pressure
plate and the compression springs. Should any sign of scoring, overheating
or distortion be present,
change the assembly.
Depress each clutch finger in turn and release it slowly to check the action
of the release mechanism. Fig. E.4 illustrates the type of release mechanism
fitted; the anti-friction pivot for the clutch fingers and the pivot plates
are clearly shown.
The clutch pilot bearing located in the centre of the flywheel is a ball
race. The bearing is packed with lubricant on assembly and does not require
lubrication in service.
To remove the clutch pilot bearing from the flywheel
engage the legs of the puller. CPT.7600-3, behind the bearing and
tighten the nut on the centre bolt to extract it. Alternatively, if the
puller is not available, the bearing may be driven from its mounting
after removing the flywheel, using the driver. Wash the bearing
thoroughly in petrol or paraffin and check for signs of wear.
Replace the clutch pilot bearing using tool No. CPT.
7061. Care must be taken to locate the sintered bronze pilot bearing
correctly in the flywheel with the flat face of the bearing towards the
engine and the shouldered face towards the clutch disc. If the bearing
is of the early ball bearing type, it must be repacked with a suitable
high melting point grease and then fitted with the shielded face towards
the clutch disc and the open side towards the crankshaft.
Place the clutch disc in position on the flywheel face
with the longer shoulder at the hub towards the gearbox. Align the disc
with the pilot bearing, using locator P.7059.
Refit the pressure plate assembly. Replace the six
securing screws and spring washers, tightening them evenly. Remove the
clutch disc locator.
To remove the clutch release bearing, disconnect the
retracting spring, remove the spring clip securing the rubber gaiter to
the release arm and detach the gaiter. Pull the forked end of the
release arm out of the spring clips at the rear of the bearing hub and
disengage the arm from the fulcrum pin. Pull the hub and bearing off the
main drive gear bearing retainer and withdraw the release arm.
To dismantle the clutch release bearing assembly, hold it with the
bearing downwards and tap the shoulder of the hub sharply on the bench.
Reassemble the clutch release bearing. Check that the release arm
fork spring clips on the rear face of the hub (illustrated in Fig. E.1) are
in good condition and assemble the new bearing on the hub with the thrust
face of the bearing away from the hub. Suitably support the bearing
on the bed of a press, leaving sufficient clearance for the shouldered end
of the hub to protrude. Press the hub into position, ensuring that it enters
squarely into the bearing bore.
Pass the clutch release arm through the aperture at the side of the
clutch housing, with the fulcrum pin spring clips, shown in Fig. E.1, facing
towards the rear. Engage the clips around the fulcrum pin load.
the machined sleeve of the gearbox main drive gear bearing retainer for
burrs. etc., lightly smear the sleeve with high melting point grease and
replace the release bearing assembly, engaging the forked end of the release arm in the spring clips on the
hub. Check that movement on the outer end of the release arm is freely
transmitted to the bearing. Refit the rubber gaiter to the clutch release
the gearbox or engine whichever has been removed.
CLUTCH RELEASE BEARING
must be taken during service, that the correct clutch release bearing hub is
fitted. Clutch release bearing hub Part No. EOA-7561 differs from the hub
Part No. 204E-7561 by the length of the machined surface from the front face
of the hub to the shoulder which abuts the rear of the release bearing.
If the bearing hub, Part No. 204E-7561 is erroneously fitted in placc of the
hub, Part No. EOA-7561 the release bearing will be located too far forward
on the hub, and may, when the clutch is depressed, cause the clutch fingers
to foul the clutch disc.
For ready identification, the length of the machined surface referred to
above and the corresponding gap between the front face of the hub flange and
the rear face of the bearing when correctly located, are tabulated in the
'Specifications'. The release bearing is of the pre-lubricated type and
should require little attention in service.
Remove the gearbox assembly as described in section C.
Where a rubber gaiter is fitted on the clutch release arm, detach the outer
clip and pull the gaiter off the arm.
Pull the forked end of the release arm out of the
spring clips at the rear of the bearing hub and disengage the arm from the
fulcrum pin. Pull
the hub and bearing off the main drive gear bearing retainer.
3. Hold the release bearing assembly with the bearing
downwards and tap the shoulder of the hub sharply on the bench, when the
bearing can be removed from the hub.
Check that the spring clips on the rear face of
the hub are in good condition and assemble the bearing to the hub with
the flat face of the bearing away from the hub shoulder.
Suitably support the bearing on the bed of a press,
leaving sufficient clearance for the shouldered end of the hub to
Press the hub as far as the shoulder, ensuring that it
enters squarely into the bearing bore.
Pass the clutch release through the aperture at the
side of the clutch housing, with the spring clips to the rear. Engage the
clips at the lower end of the arm around the fulcrum pin head.
Check the machined sleeve of the main drive gear
bearing retainer for burrs, etc. Pack the pocket at the rear of the hub with
high melting point grease and replace the release bearing, engaging the
forked end of the release arm in the spring clips on the hub. Check that the
hub moves freely on the main drive gear bearing retainer and that movement
of the outer end of the release arm is freely transmitted to the
When fitting the clutch release arm gaiter, locate the
square wire clip in the larger diameter of the gaiter, and position it on
the release arm, larger end first, so that the end of the gaiter fits inside
the aperture in the housing (see Fig. E.1). (It is essential that the edges
of the aperture are free from burrs and sharp corners). Fit the smaller clip
around the outer end of the gaiter and push the gaiter up the arm until the
cut-out in the end of the gaiter fits round the depression in the release
arm and clears,the push rod adjusting nut.
Replace the gearbox assembly as described in section
CLUTCH PILOT BEARING
bearing serves as a mounting for the forward end of the main drive gear and
only rotates relative to the main drive gear when the clutch pedal is
bearing is of the sintered bronze type and it is most important that it is
fitted square in its bore in the flywheel with the shouldered face towards
the engine and the flat face towards the clutch.
a ball type clutch pilot bearing (B-7600-A) is available for service only,
together with a 0,004 in. (0,10 mm.) oversize ball bearing.
audible when the clutch is fully depressed, does not necessarily indicate
that the pilot bearing is at fault, since the clutch release bearing itself
is also rotating on the hub under these conditions. In the event of a noise
associated with either the clutch release bearing or the pilot bearing, the
following test will enable the sound to be located.
Press down the clutch pedal with sufficient pressure to
cause the release bearing to rotate without freeing the clutch. If the sound
is then heard, the noise is definitely associated with the release bearing.
If the noise increases when the clutch is fully depressed, then the
additional noise may be due to a worn pilot bearing in which case it should
Remove the gearbox assembly as described in the 'Gearbox'
Remove the clutch disc and pressure plate as described
on page E.4.
Withdraw the bearing from the flywheel, using Tool No.
AT3/U7600-A. If the pilot bearing is being removed from the flywheel on the
bench, the driver AT/U7600-B
may be used to press the bearing from its flywheel location.
Locate the new pilot bearing in its location with the
flat face of the bearing towards the clutch disc and the shouldered face
towards the engine.
Tap the bearing into place. using the driver AT/U
7600-B, ensuring that it is fitted square in its bore. This latter point is
most important, as an incorrectly fitted bearing will quickly wear and cause
clutch noise and vibration.
Replace the clutch disc and pressure plate assembly as
described on page E.4.
Replace the gearbox as described in section C.
SPECIFICATIONS AND REPAIR DATA
Clutch disc linings:
8,5 in. (203,2 mm.)
5,75 in. (146,0 mm.)
0,16 in. (3,86 mm.)
Number of springs in clutch hub:
6 - Green
Outside dia. 8,64
in. (219,5 mm.)
0,47 in. (11,94 mm.)
springs: 6 - brown
with blue paint mark
189-199 lbs. (85,73->90,3 kg.) at compressed length of 1,6 in. (40,84