> What is the ideal adjustment for the clutch cable?
Hey Steve! Hope this helps!
Remember there is the entire Maintenance Manual in the Members Only
section @ Amphicar.com
Clutch adjustment
Since the clutch is subject to wear, it is important at the
specified ser?vicing times, to check and to correct the play. Play of
the clutch pedal should be .75" (Fig. I a), play between release
lever ring and clutch ring-.06". When adjusting the clutch, it is
necessary to dismantle and remove the back seat and seat rest as well
as the seat base (see 11/4)
Fig. land 2). When adjusting the clutch play (Fig. 2) follow
specifica?tions exactly as indicated, as the clutch is subjected to
great wear and tear, when the clutch play is too low. If the clutch
play is too great, it is possible that the clutch will not disengage.
This puts excessive stresses on the gear Synchromesh
If it is found that the clutch does not disengage even when the
clutch play is correctly adjusted, the clutch must be dismantled and
overhauled.
Dismantling and reassembly of clutch
Remove engine (described on 1/13) and place on a workbench
Disassemble clutch housing securing bolts (Fig. 1 ), lift off clutch
housing.
Loosen securing bolts, holding the pressure plate to the flywheel
plate evenly and crosswise, so as not to deform the assembly (Fig.2).
Mark pressure plate and flywheel plate, to avoid any imbalance when
reusing (Fig.2a).
Remove clutch pressure plate assembly and driven plate (Fig 3) The
arrows indicate both dowel pins.
Checking of clutch
After dismantling the pressure plate assembly, check the bushing in
the crankshaft and the pin of the drive shaft for wear and tear. The
maximum permissible play between the pin and the bushing guide is
006". Replace bushing, if play is excessive
At each dismantling of the clutch housing it must be checked for
cracks as well for deformation, warping and unevenness of the joined
surfaces If faulty, replace
This inspection must be carried out with extreme care, as, in case
of warping of the clutch housing, not only will the driven plate be
subject to excessive stress, but also the drive shaft of the gear-box
The bearing of the release fork for the clutch in the gearbox, as
well as the springs and the clutch ring with the form springs must be
checked If the parts are worn out, they must be replaced
Clutch automat
To replace the release lever plate bolt the clutch to a clutch-
tensioning device and tighten the release lever plate with the center
pinion. The retaining release lever springs are removed from their
support on the release lever plate and the center pinion of the
tensioning device is loosened
Note If no clutch tensioning device is available, use a post drill
by pressing the mandrel of the drill against the release lever plate
and thus being able easily to lift the retaining release lever
springs (Fig 4)
It is not recommended to dismantle a clutch pressure plate assembly
if no clutch tensioning device is available (for example, if the
pressure assembly plate is worn out, or the release lever is warn
out, or in cases of reduced pressure of the springs due to
overheating).
In such cases it is recommended to replace the clutch.
Checking of driven plate
Check clutch facings for wear If worn facings, oily facings or
scarring is found, the facing must be replaced. When the facings are
riveted on, the driven plate must not be deformed. The rivets must be
headed correctly, for they must not, under any circumstances,
protrude from the facings Driven plate with damaged torsion springs,
or their mount?ings, must be replaced Maximum permissible side play is
12". Check the vertical play of the hub on the splines (04") and the
backlash .16".
If the driven plates do not glide freely on the splined shaft, the
fault must be remedied, for this could cause difficulty when
disengaging the clutch
Assembly
When reassembling the clutch, act in reverse order than during
dismantling. Pay special attention to the following
When fitting the driven plate and the pressure plate, a guiding tool
is absolutely required in order to center the clutch exactly
Otherwise difficulties may arise when fitting the engine into the
gearbox, as the drive shaft of the gearbox will not line up with the
spline of the driven plate and into the guide bush of the crankshaft
(Fig 1)
Pay attention to the marking of the flywheel and of the pressure
plate (to be done when dismantling), so that it can be remounted in
its original position.
Tighten the securing bolts of the clutch pressure plate assembly
evenly and alternately.
Fig 2 shows the release assembly in the gearbox
