TM 5-3810-300-24 & P2
10. Try the cover assembly on the flywheel without the disc assembly to check fit where cover is piloted at O.D.
11. Install driven disc, making sure that it is properly positioned and insert an aligning shaft. Normally the long end of the
driven disc hub extends toward the transmission, but in a few instances the long end may face toward the engine.
Make sure that the driven disc hub does not come within 5/32 in. of the pilot bearing.
12. Bolt the cover assembly to the flywheel, tightening each cap screw gradually until the cover is drawn up tight.
Extreme care must be exercised to make sure flywheel ring or cover is seated in pilot rim on recessed type
SOME COVER ASSEMBLIES ARE BOLTED TO THE FLYWHEEL BY CAP SCREWS WITH A
GROUND SHANK WHICH FITS THE REAMED HOLES IN THE COVER. THE MACHINED SHANK
EXTENDS THROUGH THE COVER INTO A RECESSED OR COUNTERBORED HOLE IN THE
FLYWHEEL. IF A FLYWHEEL HAS BEEN REGROUND THERE IS A CHANCE THAT THE
COUNTER BORES COULD BE TOO SHALLOW AND MAY REQUIRE DEEPENING. IF THE
FLYWHEEL HAS BEEN REMACHINED SEVERAL TIMES TO REMOVE HEAT CRACKS OR
SCORES, THE COUNTERBORED HOLES MAY NOT BE DEEP ENOUGH TO ALLOW COMPLETE
TIGHTENING OF THE CAP SCREWS. THIS WILL NECESSITATE REPLACING THE FLYWHEEL.
Clutch Actuating System.
1. The master cylinder and slave cylinder hydraulic system must be purged of air. This is done by opening the bleed
screw on the slave cylinder and pumping the master cylinder with the clutch pedal until the air bubbles at the bleed
screw stop. Tighten the bleed screw to prevent loss of fluid after the system has been purged. This operation is
similar to bleeding a hydraulic brake system.
2. Check clutch pedal Free Travel by hand rather than by foot to make sure proper linkage clearances have been
made. Free Travel is the first easy movement of the clutch pedal. There are two distinct Free Travel ranges. The first
range is approximately 3/8" and it offers no pedal resistance. It is the result of the master cylinder primary cup. The
second range is approximately 1 3/4" to 2" and it results from the clearance between the adjusting screw and the crank
on the clutch housing.
It is important when making clutch linkage adjustments, that the master cylinder piston does not "bottom out" against the
push rod. If properly adjusted, there will be approximately 1/32" free-play between the master cylinder push rod and
piston when the clutch pedal is against its stop. This clearance will ensure the complete return of the master cylinder
push rod and will allow the piston primary cup to clear the master cylinder bypass port. The 1/32" clearance is to be
determined by the looseness in the push rod when the clutch is engaged. With the piston in this position , fluid
movement through the bypass port compensates the closed hydraulic system for fluid expansion or contraction due to
temperature change and for seepage. Failure to properly release expanded fluid could result in a slipping clutch and
premature clutch failure.