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PropellerShaft Clutch

Repairsand 1976-
Contentof Manual

Specifications I
SpecialTools 1
spar€ Pafts lllustlation. , , 2-3
R e p l a c lcnlgu t cohp € h t i ncga b l e. . . . . . . . . . . . . . . . . . . . . . . . . . 5
R e p l a c icnl gu l c ph e d a l / b u s h. i.n. .g. . . . . . . . . . . . . . . . . . . . . . . . 5
Removing clulch 5
Clulchtacingrgplacemenl 5
Servicing pilolbearing
Clulchcafiiorinspection ,, 6
chltchinstallation,,.,,,,. 7
Additional infomalion 7

Group45: PropellerShaft
Description. . . . . . . . . . . . . 1
SparePartslllustrations 2
Servlce procedures
Replacingsupportbearing 4
Propellershall 4-5
Re-building U-joinb. . .... 6-7

NOTE:All referencesio Model2.40in lhis manualalsoapplyto DL,GL and GT.

NOTE:All referenceslo l\rodel260in rlis manualalsoapplyto GLEandCoupe.





Speciticat,ons ,I
Special Tools ,I
Spa.e Pans lllusvano. 2-3
Service Proceduresi
Repracng clutch operatng cab|e 5
Replaong clurcf' pedal'bLshrT 5
Bemoving clurch 5
C l u t c hf a c i . gr e p l a c e m e n . .t. . . . . . . . . . 5
S e r v i c i npgr l o rb e a l n q . . . . . . . . . 6
C l u t c hc a f f , e irn s p e c t i o. n. . . . . . . . . . . . . 6
Clurch Insrallalion 7
Additional information 7

260 GLE& Coupe 240,DL,GL,GT Diessl
Size . . . . . . . . . . . . . . . . . . . . . . . . . . 9" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V2"
Throw-oul yoketravel,,..,,..,,.0 mm 0.00" , , , . . , , . , , , . , , . . . , , . . , . .3-5mm 0.12=O.2O"


2824 Mandrel


Sparc Pans lllustration

240 l


o 'l



Clutch 3

Replacing clutch assembly

Two diflerenl designsol pressureplates and release
bearings arscufientlyusedin production
ol Modsl240
(DL, GL, GT and Di6s€l)and Modol260 {GLE and

lrodel 240 (DL, GL, GT and Diesel)

Thefingersoftheprassureplaleare straightandmust
us6lhs corosponding roleasebeafing,as shownon
Thereleasebearingis ,$ mfi (1- 11/16") in
240 ilod€l
B€arlng No. 672122-9 Thispressure plaleisiheonlyonecurrently
Prcrlurc Plaie No. 34124$2 ourSparePartsDivision-onlythelongerreleasebear
ing is lo be used.See Fig.1.

itodel 260(GLEandCoupe)
The fingercol lhs prsssur€plate ars €ised approxi-
mately7mm (9/32") al the c€nter.Consequently a
shonerrsleas€bea ng is 36.5mm(1-716")in length.
When replacingths clrlch pressurc plate ass€lnbly,
car€is to be takento use onlylhe matchingshorler
bearing.See Fig.2-

IMPORIAI'IT:Pressureplatesand releasebearings
musl ahraysbe ol lhe coflect combinationand should
neverbe interchanged.

260 flod€l
Belrlng l'lo. 381213{
Pr$surc Pl.r€ No. 3812()7{
Flg. 2
Clutch operaton

Replacing clutch operating cable 3. RemovereLeasebearing.Disconnecicable fiom

re easefork. Slackencable sheathfrom bracket.

I P u rf r o n re n oo ^ s r a _ d sq. F m o v eu _ d e - d a s hp a

2. Firstrer.ove ret!rn spr ng.Thendisconnectclutch

c a b e a t c L r l c hf o r k . P u l l o u t c a b l e .
3. RemovecLevispin al cable upper efd. Pull cable
olt of rubber grommet in fnew6 .
4. Push new cable into the rubber grommei in fi
rewaLl.Re insraI clevis pin.
5. F i i a d j u s t m e ndte v i c eL n t h eb € l l h o u s i n gC.o n n e c t
cable to cluich fork. lnstall return spring.

4. Remove bolts. Remove flywheel housing.

5. Remove bolt for re ease fo.k bE Ltoint. Remove
&ll and releasefork.
6. Removebolts holdingc utch to flywheel. Loosen
6. Adjusiclulchtork free pay to approx.3-5 mm them crosswisea coupe of turns at a time to
(1/8',). preventwarping.Removeclutchand clulch plate.

Replacing clutch pedal/bushing

The lnslructions below cover repacement of pedal

1. Removeclevispin securingcabe lo clutch pedal.

Remove nui, pull out bot and remove pedal.
2. Remove tubular shaft. Dfive out bushingswilh

3. Pre-Lubrlcatenew bushingswith greaseand install

them. lnstall tubular shaft.
4. Positionpedaland sttach bolt. lnstalland torque
n!t. Reconnectcable and clevis pin.

Removing clutch
R e p a c ec l u t c h d s c ( c l u t c h )
1. Remove transmissionaccordingto instruciions.
2. Remove upper bolt ior starler motor. Clutch facing replacement
1. Drillout vetswitha drillhaving
vets,3.5 mm (9/9"). Removeod lacings.

Clutch 5

Clutch carrier inspection

As the clulch caftier cannot be disassembled, it nrust
be replaced compete. Ch€ck the clurch carefully.
Checkpressureplatefordamageby heat,cracks,scor
ing or other damage pn the friction surface. Check
the curvatureof the pressureplate with a sieel ruler,
5. Hlb which ls placeddiagonallyacrossthe friction surface
3, Spring
of the pressurcplate. Then measurethe distancebe-
tween the slraightedge of the ruler and the inner dia-
2. Checkclutch plate.The indentationson the ton meter oJ the pressureplate.This measurementmust
gues should be even.The clutch plate must not not exceed0.03 mm (0.00012").
be warped. The clutch springsand rivets in hub
should fit securely and not show any signs of
looseness.Checkto make sure that there are no

lf the clutch plate has any defects,ir should be

3. Rivet new facings (preferaby in a ivet presd.

NOTE|the riversshouldbe insertedfrom the side
o_ wl..h rhe fac a9 lies aad |veled fro- rhc op
posite direciionagainstthe disc.Use every other
ho e in thefacing.After riveting,thefacingsshould
Cheking cuMluro of pressureplate
be spacedfrom each other as determinedby the
1 d . ' r a r o - s o n r l - e" l u r . h d , s c . l - | sr s m o s r r r
portant in orderto achievea smooth engagement
when slarting and druing.
The clltch facings must be absoluteLy free from
oil. Oil on the facings can causeclutch grabbing.
There musi be no "crown ng', i.e.cearance between
the straight edge of the ru er and the outer diameter
of the Dresslre plate.Check at severa points Check
Servicing clutch shalt pilot bearing the pressurespdng carefully.lf il is crackedor darn-
1. U s e p u l e r h a m m e rt o r e m o v ep i l o t b e a r i n g . agedin anyway, the€lutchshouldbe replaced.
lf bearing, after ceaning and light oiling, ruis C h e c t r l - e r e l e a s eb F a r i n gb v r L r - 9 , r a f p w r r e 5
smoothly and evenlyand has no noticeabe play, under light pressureso ihat the balls rotate against
r sroJld ba packedwrh ba I bed'irq S' ._d ihe races.The bearingshouldturn easilywithoLrtbind-
ing at any point.The releasebearingshould also slide
N o - t : h e d r e s ' s r a n q e a s ps l ' o u r db e u s e d e d s i l yo _ t h " g - , d e s l e e v ef r o - r h e , a . s - r s s o r .

6 Clutch
Clutch installation
Beforelnsrallaton,checkthar clutch facingg flywheel
ard pressureplateare completelyfree from oil. Wash
rher wlll_ gasoli.e a.d wipe ort wilh a Llean p'ece

1. Set up rhe clutch plate khe longest side of the

hubfac ng backwards)togetherw th clutch.lnsert
centering mandre 2484 as a guide in the pilot
b e a r i n gi n t h e f l y w h e e .
2. Install six bolts which hold the clutch. Tighren
them crosswisea couple of tlrns at a time. Re-
move cenler ng manorer.
3. lnstall releaseyoke in flywheel housing.
nstal upper bol for stalter motor in the housing
and install rhe housing. Install bolts in the fo- 5. Insertcableshaft ln bracketand rear nut. Secure
l o w i n go r d e r :F n * f o u r u p p e r( 7 / 1 6 ) b o l t s ,a n d cable in releasefork. Install releasebearlng-
then ower bohs for ihe srartermotor, and finaly 6. Installandtighten nul for the upperstarter motor
two ower (3/8") bolts. The nu for rhe starter
l.rlotorupper bot is installedafrer ihe cabe has 7. I n s r d lr h p r r d r s - s s r o la c c od , n g o a s r u c , o n " .
L Adlust cutch pedal play.

It is possibletoinstalitherubberwasher
on clulchcableincorreclly. willcauselhe rccessedpadot
lhewasherlo Jacethewrongdirection. Thiswillprevenllhesteelwasherfrombeinglocatedin itsseatandwillcause
lhe rubberwasherto crackandeventuallv Jallofl,
As aresultoltheincorrectinstallalion,
lhec utchwilldevelopanabnormalslipduing Premature
lailureol lhe clulchdiscmayoccur.



I Desc ption



Description 1
S p a r eP a r r sl l l u s la r , o n s 2

B e p l a c i r gs u p p o r lb e d ' i n g . . . . .

Re-buildinsU-Joints 6


2 4ab

Prop€llershaft with suppon be.ring

Flangeon transmision 7. Rear onive€l joint

5 . Intemediate univeGaltoiil L Flange on rear axle
Front seclion of propeler shaft 6.

The propellershaft is a divided,tubular type shaft,

see Fig. above.The front section rear end is formed
as a splined sleeve.The coffespondingsplined shaft
cafties one of the intermediateuniversaljoint yokes.
The front sectionreaf end is supportedby a ball bear
ing. The ball bearing is in turn installedin a rubber
bearing housing,which is attached to the propeller
shaft tunnelwith a cover,see Fig-,right.The propeller
shaft has three universaljoinrs. Each joint coinsists
of a cross with four trunnions which are carried in
flange yokes by needle bea nss.
A propellershaftis pairedand balancedasa unit. F ont
and rearsectionsarc individuallymark€dwith a yellow 8. Bearseclionoi propeler
dot and an aiiow. The propellershaftmust be replaced 2,
only as a paired unit and the front and r€ar sectjons 3. 9. nubbefcover
haveto be insr€lledso thar the aiiows (the dots) point 5. 1 1 . S u s p e n s osnp r i n g

Sparc Pafts lllustrction

Propellershafts Th€ centerbearinguseddependson typeof tribular
to typeot transmission
and type 1140or 1310com- shaft.1140
hasatubediameterof /|4.5mm = 1.7520"
panionflange,and,to a certainextent,the diamete. and l3l0 a tube diameterof 50.8 mm = 2.m0".


lala 12'7t

As a generalrule, all 4'cyl. modslsexceptstaton wa, All slaton wagonand 6 cyl. modelsare equippedwittl
gonsareequipped withlhe lighlerpropeller
shafl1140 lh€ h€avy-dutytypeprcpellershatt1310witl50.8 mm
mm (1.753")ltibularshaft. (2.002")lubularshatt.
Sparc Patts Illustration


Renoval disassembly


Replacing support bearing 3. Pre$ the old beainsout of the rubberhousing

Inslallsupporlbearingandolherpa(s in reverse
1. Jack up the vehicleand put it on stands Slacken oder 10femove,lf lhe splinedjointappearsdry,
the propellershaft from the rear axleflange.Bend lubicaleit with greasemixedwilh molybdenum
back the lock washer and removethe nut at the (Molykote.)
sliding joint. Pull our the propellershaft to the lvake sure that the aiiows point toward each
other on propellershaftspairedand balanced
2. Loosen the support bearing cover. Pull off the
complete support oearrng.


Removal Disassembly
Jack up the vehicle.Slackenthe propellershaft from Propellershaft disassembly
the transmissionand rear axle flanges.For 245 use 1. Bend back the lock washer and remove the nut
impact air wrench and specialsocket 2846 to loosen for the suppon bearing. Renrovethe propeller
the bolts. Loosenthe support bearlngcover and take shafl rea' seclron.Pull ofl the supoon bearng.
down the complete propeller shaft. 2. Take the suopod bea'irg our of Lhe hoLsr.g.
Fot 242 artl 244 use rool 2779 for the front flange
bohs and tool 2846 for the rear flange bots, see Fig. Disassemblinguniversaljoints
I Removethe snap rings which secufe the needle
bearings in the yokes, see Fig. below:


2. Seclre the shaft in a vise so that the universal

tornrcom.s as nea as oossiblpto the vise raws.
Rememberthat the propellershaft is tubular and
can easily be deformed.
3. use a hammerand metalpunchto drivethe spidel
as far as it wi go in one direction.The needle
bearing will then come about half way out.

Then drive th€ spider as far as h will Assembly

opposrle direcrion,see Fig.
Assemblins universaljoinls
1. li old needlebeanngsareinstalled,checkrhatthey
are fLlledwiih greaseand rhat the rubb€r s€als
o e n o r d a - a g e d N F w b F ai n S \ - r o u d b - h " l i
f led wlth grease.
2 . . r n F r o r d e. r h . f a S e y o r a . P . " \ r 1 pp d
\ er n one direcl on so rhat the neede bearnq can
be nstalled n the trunnion, see Fig. belowi

.ar\ *tu:=

spider,fn step _-------:-

5. Drive out one of the needlebearingswhh a thin

m e t a p ! n c h .R e m o v et h e s p i d e rs. e e F i g .b e o w :
D r i v eo l t t h e o t h e r n e e d e b e a r i n g .

Then pressln ihe neede bearinglar enoughthat

the snap ring can be insta ed. Use a dfift with a
diameter sLightly ess than that of the f€edle

3. Insrallthe oth€r neede bearingand repear the

Do the sam€on the remainingyoke-

Insiallaiion s n r€verseorder to remov6.

ll is exlrerney mporlantlhal lhe propellershaft is
slraighl.The inspecUon musl be carelulsinceeven
minordamageon lhe propeer shatlcancausevibra-
ton. The shatlshoud be set up betweencenlersand
checkeda ongils entirelenglhwilhan indicatorgauge
whilerl s olalr'lg.
ll irrsoJr-ol-true
rorelha']025 nm
(0.010")lhe shaflmustbe replaced.
NOTE|No artenrplshoud be madeto straightena
T \ o m r e r l _ es J p o o f lb p a l n q D . - s sr l e b p " i - 9 , a c . .
aga nsl each other by hand and lurn them n opposte
directions.The bearng shoucl run easiy without bind
, - g a r a r\ p o i r l ' I b i d 5 - a o r l . e b . a r 1 9 J o . e .

Group 45


:::::::::::::: A:I B
: 9995019::::::;::(: Instructions for press tool 999 5O18 and pull-
er 999 5019

B. Arbor
C. Rod
D. Suppoft.
Parroi 9995018

Disassembling universal joint

Removethe lock r ngs and positon the U joint in the
press tool. Use the peda 10 move rhe spider. tf the
power is not sufficient, use a€r on rhe rod.

Movethe U jo nt io the puller.Align rhe needlebearing

between the jaws. Pressdown the handlewhich w ll
remove the needle bearing.

Assembling joint
Locate the spider with seals n one of the coLrping
flanges.Locateoneneedlebearng. Posltionthe U-joint
n the presstool and pressin the needlebearingunti
I the lock ring can be insralled.Turn the U-joint over

f, and press in ihe other needle bearing.Inst.ll spider

and neede bearingsn the sameway in the other co!-
pling fLange.
nstall the lock rings.

Gtoup 45
Replacingpresstool arbor
Loosenlhe screwandremovethe arbor.Positionthe
other arborand tightenthe screw'
NOTE:The largearborhastwo recesses to be po-
this reasonit is providedwith
a hole corresponding with the screw

Removethe O-ring and use a punch to pressout the

Jaws for sm8ll U-joints 9999 026

Jaws for large U-joints 9999 027

Lift the ring and bend

Holdthe leverin the upperpositionand pressthe jaws

into position. Positionthe ng with ths side marked
"up" upwards.Installthepins. Bendthsspring, which
rctainsths lowerendsof theiaws, into position.Install
the o-ring.

Gtoup 45

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