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Lotus Service Notes Section QH Page 7 2. Friction plate: Check the cush drive springs for breakage or cracking of the hub. Examine the condition of the friction material for signs of oil contamination, scorching, or any other damage. Using vernier cal- lipers, measure the depth of the rivet heads below the surface of the friction material.
Minimum depth: 0.3mm.
With the friction plate mounted on its splines, check the run-out at the outer edge of the friction surface: Maximum run-out: 0.8mm.
If addressing symptoms of clutch judder, or if any of the above inspections are not passed, renew the friction plate. 3. Release bearing: Check the bearing for discernible play, noise or rough feeling, and renew if there is any doubt. 4. Flywheel: Using a dial test indicator, measure the axial run-out at the outer edge of the flywheel drive surface.
Maximum runout: 0.1mm.
If necessary, renew the flywheel. When fitting the flywheel:
- progressively tighten the eight fixing bolts in a diametrically opposite sequence, to 49 Nm.
- mark the angular position of each bolt head, and further tighten each bolt in a diagonally opposite se- quence an additional 90°. Refitting clutch assembly 1. Using a universal type centralising mandrel, position the friction plate with the 'flatter' side towards the flywheel, and fit the clutch cover onto the flywheel dowels with the match marks aligned (if applicable). 2. Fit the clutch cover retaining bolts finger tight and monitor friction plate centralisation as the bolts are progressively tightened in a diagonally opposite sequence to 19 Nm. 3. Using a dial test indicator, measure the diaphragm spring tip height variation. Maximum variation: 0.5mm.
If necessary, use a special clutch tool to achieve the specification. 4. If the release fork pivot ball had been removed, refit and tighten to 37 Nm. 5. Apply sparing quantities of Molybdenum Disulphide (MoS 2 ) grease to the contact points of the release fork fingers, release fork pivot, fork retaining spring and pushrod socket. Also apply sparingly to the transmission input shaft splines. 6. Fit the release bearing and fork together, and position in the clutch housing with the fork retained on the pivot ball by its retaining spring. Fit the dust boot into the housing aperture. 7. Refit the engine to the transmission in reverse order to removal, tightening the clutch housing bolts as follows:
M12 x2; Upper 64 Nm
M10 x2; RH side 37 Nm
M10 x2; Starter Motor 37Nm
M10 x2; Sump 23 Nm
Illustration overleaf. Updated 9th June 2010 |