ENGLISH

TECHNICAL BULLETINS
TECHNICAL BULLETINS - ENGLISH
LB120 CRITICAL DISC / FLYWHEEL MATCH LB133 CRITICAL RELEASE BEARING / FORK
Vehicles: 1987-93 5.0- and 5.8-liter Ford F- and E-Series Vehicles: Jeep CJ, Cherokee, Wrangler and Comanche
When replacing the clutch, match the disc to the flywheel Release bearing/fork combinations differ among models,
prior to installation. A mismatch can cause contact and the parts are not interchangeable. The wrong
between the disc damper and the inside diameter of combination will result in chatter and hard pedal when
the flywheel. Although the clutch may function properly the fork contacts the bearing retainer. Following is a
initially, release problems will result. A similar situation description of how to identify the two types.
results when the disc is installed backwards. Prior to Models through 1979 used a fork with two small pin-type
installation, ensure the disc damper fits into the flywheel locators at the bearing end. The locators fit into holes
opening with proper clearance. drilled in the release bearing plate under the clips. When
installing the release bearing, ensure the locators fit all
the way inside the holes in the release bearing plate.
LB122 JEEP RELEASE PROBLEMS
Vehicles: 1980-86 Jeeps After 1979 the fork had no locator pins. Instead it was
centered by a release bearing collar that extended
Excessive wear or misalignment at any of the release
beyond the back of the bearing between the bearing
mechanism components will cause insufficient slave
retainer clips. When replacing the fork, ensure it is wide
cylinder travel. Check the condition of the pivot, washer
enough to pass freely over the centering collar.
and seal attached to the end of the slave cylinder on
models with external slave cylinders. If any of these
parts are missing, cracked, or severely worn, release
problems will result.
LB134 RELEASE BEARINGS REPLACEMENT
Vehicles: 1974-02 Volkswagens
When installing a pull-type clutch with a release plate
LB129 FORD/GENERAL MOTORS BEARING and wire ring, cycle the clutch prior to start up to ensure
RETAINER WEAR PROBLEMS the circlip is fully seated under the tabs of the diaphragm
spring. If the clutch set contains a release bearing, you
Vehicles: 1983-04 Ford Mustang,Thunderbird; Mercury Capri
must install it.
1982-92 Chevrolet Camaro
1982-92 Pontiac Firebird The bearing fits inside the transmission. The clutch
1982-02 Chevrolet Astro, Blazer, and S/10 release arm presses against the bearing to move a long
rod passing through the transmission. The rod pushes
1982-02 GMC S/15, Jimmy, Safari, and Sonoma
the release plate to push the diaphragm fingers and
The bearing retainer on referenced vehicles equipped disengage the clutch.
with the Borg-Warner T5 transmission can wear, causing
the release bearing to bind. Binding and misalignment A sheet metal cover, usually green, must be pried out
may cause hard pedal, improper release or clutch for access to the release bearing. This typically results in
chatter. To avoid problems following installation, replace the destruction of the cover, which must be replaced to
the bearing retainer. prevent transmission oil leaks. Also inspect the release
rod for wear or bending, the lever for cracks and the
shaft for spline damage.
LB132 CHEVROLET, GMC AND DODGE
TRUCK RELEASE PROBLEMS LB135 PREVENTING SQUEAKS
Vehicles: Chevrolet, GMC and Dodge Trucks
Vehicles: 1995-84 Chevrolet/GMC Trucks
Use of oversized lock washers on the clutch mounting
Insufficient lubrication between the fork and the ball stud
bolts of these trucks with 12-inch clutches can cause
may be misdiagnosed as a release bearing problem.
release problems. The larger diameter of the washers
Light pressure on the clutch pedal will silence the noise
can extend through the cutouts in the clutch far enough
temporarily. Lubrication of the pivot ball-to-fork contact
to contact the disc. Use only standard 3⁄8-inch diameter
will eliminate the problem. To speed future lubrication,
lock washers or threadlocking compound and torque the
install a grease fitting.
bolts to manufacturers’ specifications.
The 1984-93 S- and T- Series with Borg-Warner 5-speed
transmissions (ML2, ML3, MW1) require a pre-drilled
pivot ball and matching release fork. Locate the raised
boss on the outside of the bell housing that is directly
in-line with the center of the pivot ball mounting hole.
Drill a hole through the center line of the boss into the
pivot ball mounting hole, and tap the hole for installation
of a 1⁄8-inch NPT grease fitting. Lubricate the pivot ball
and reinstall the transmission with a pipe plug instead of
a grease fitting. This will prevent over-lubrication of the
pivot stud during normal maintenance.
For additional information, refer to GM bulletin
#16-73-01. For specific information on the procedure for
1994-95 C/K and S/T Series, refer to GM bulletin #56-73-01.

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LB145 INSTALLATION OF RELEASE BEARING LB150 CLUTCH CHATTER CAUSED BY

AND SLEEVE IMPROPER DRIVESHAFT ANGLE
Vehicles: 1988-90 Ford Escort, 1988 EXP, Vehicles: 1988-94 5.8- and 7.5-liter Ford F250 4x4
1989-95 Taurus SHO, 1988-94Tempo; Supercab with 155-inch wheelbase
1988-94 Mercury Topaz Chatter at takeoff may be caused by extreme driveshaft
Vehicles with MTX transmissions have a one-piece angle between the transmission and the differential.
aluminum housing with integral bearing retainer Replace the driveshaft center support bearing plate with
prone to severe wear. The wear results in binding and Ford part #F4TZ-4831-A to eliminate the problem.
misalignment of the release system. Clutch sets for these For additional information, refer to Ford bulletin #94-16-19.
applications contain a stamped steel sleeve to renew
the sliding surface of the bearing retainer. The revised
release bearing is designed to retain the proper bearing- LB151 NO RELEASE
to-retainer clearance when used in combination with the Vehicles: 1986-94 Dodge Colt; Eagle Summit, Talon;
sleeve. This allows servicing of the one-piece housing Hyundai Elantra, Excel, Scoupe;
without replacing it. Install the sleeve until the flange Mitsubishi Eclipse, Mirage, Precis; and
bottoms against the transmission housing. Plymouth Laser
The roll pins securing the release fork to the cross shaft
One Piece Housing can fatigue and break. This enables the fork to turn on
Input Shaft Steel Replacement the shaft. Replace the pins and ensure they fit snugly in
Sleeve the holes. Replace the fork if necessary.

LB152 HARD PEDAL

Vehicles: 1990 1.9-liter Ford Escort
The release bearing cross shaft is supported by plastic
bushings in the transaxle. Bushing wear can cause a
Original Bearing binding cross shaft and hard pedal, resulting in flexing
Contact and cracking of the firewall in the area of the cable.
Install the steel sleeve until the flange bottoms Always replace the bushings. Check the release system
against the transmission housing as shown. and all attachment points for damage.

LB146 12-INCH CLUTCH UPGRADE LB153 GROWLING NOISE

Vehicles: 1987-94 7.3-liter Ford F Series Vehicles: 1994 5.0-liter Ford Mustang
A 12-inch clutch upgrade, recommended for all non- A “growling” noise may be heard when the clutch is
turbos and vehicles equipped with aftermarket either released or engaged at higher engine speeds. The
turbochargers. The upgrade replaces the original noise is caused by vibration at the connection between
11-inch clutch. When installing the clutch, ensure the release fork and cable. Install an isolator dampener,
the correct Dual-Mass flywheel is installed. Ford part #F4ZZ-7C530-A, at the fork-to-cable junction to
Flywheels on different applications are balanced eliminate the noise.
differently, and interchanging them may result For additional information, refer to Ford bulletin
in vibration and driveline damage. Always install #94-20-7.
new flywheel-crankshaft bolts and torque them to
45-49 ft-lb.
LB154 PREMATURE CLUTCH WEAR
Vehicles: 1994-98 Jeep Cherokee, Grand Cherokee, and
LB149 AVOID ENGINE SENSOR DAMAGE Wrangler
Vehicles: 1988-96 3.9-liter Dodge Trucks Premature clutch wear may be caused by insufficient
Excessive flywheel machining and installation of the clearance between the bell housing and slave cylinder.
wrong mounting bolts can damage the crankshaft The slave mounting surface is located too far forward,
position sensor. The sensor is mounted on the block restricting movement. This prevents proper fork
directly behind the bolt circle of the clutch mounting movement, causing partial release and slippage. Install
bolts. Ensure the correct mounting bolts are installed a shim, Jeep part #4797072, between the slave cylinder
and a minimum amount of material is machined off the and bell housing to avoid premature wear.
flywheel.
For additional information, refer to Chrysler bulletin
#06-03-94.

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LB157 HARD SHIFTING grommets to make sure they are not damaged and
they are properly installed. These grommets prevent
Vehicles: 1990-91 2.4-liter Nissan Pickup damage from vibration.
Release problems have been caused by the disc binding 4. Install the slave without grease. To prevent damage
on the input shaft. Ensure the disc moves freely on the and leaks, do not clean the slave with solvents.
input shaft and the splines are free of galling or scoring.
5. Use the new pin and retaining nut included in the
Inspect the slave cylinder for a minimum of 12-14 mm
clutch set. Do not reuse fasteners, and avoid over-
(0.47-0.55 inch) travel. Replace hydraulic components to
tightening the flare nut to prevent cracking of the
restore proper travel at the slave and retest the clutch.
housing.
If slave travel is correct but the problem persists, check 6. Use only the manufacturers’ recommended brake
the flywheel step dimension. If the flywheel is within fluid. Make sure the fluid is fresh.
Nissan’s specifications, replace the clutch, disc, release
7. For some Jeep applications, it is necessary to
bearing and pilot bearing.
remove the “quick disconnect” fittings from the
For additional information, refer to Nissan bulletin hydraulic lines.
#NTB92-010.

LB158 SQUEALS WHEN COLD LB165 BOLT HOLES ON CLUTCHES

DESIGNED FOR MULTIPLE
Vehicles: 1988-93 3.0-liter Toyota Pickup
APPLICATIONS
In vehicles with hydraulic release systems, the
release bearing is in constant contact with the clutch Referenced part numbers contain a diaphragm spring
diaphragm fingers. A squealing noise on engagement clutch that replaces the original coil spring clutch. The
can result when the release bearing and clutch rotate at original had six bolt holes. The LuK replacement has
different speeds. If the noise stops after approximately nine holes because it is designed for use on multiple
five minutes, replace the slave cylinder. If the noise applications with different bolt patterns.
continues after the vehicle is warm, the cause is Small Diameter Large
probably the release bearing and/or the pilot bearing. To Diameter
determine which bearing is the source of the problem,
set the parking brake, put the vehicle in neutral and start
Large
the engine. If it’s the release bearing, you’ll hear chirping
Diameter
which gets louder when you slowly depress the pedal.
If it’s the pilot bearing, you’ll hear squealing when you
actuate and hold the pedal.
For additional information, see Toyota bulletin #032.

LB163 INTERNAL SLAVE CYLINDERS

Slave cylinders located inside the bell housing require
special handling to guarantee proper operation.
LB171 NO RELEASE
1. Do not cut the plastic straps. They are designed to Vehicles: 1984-98 Ford Aerostar, Bronco II, Explorer,
hold the hydraulic piston in place during installation. Ranger; Mazda B2300, B3000, B4000, Navajo
They will break free the first time the clutch pedal is Referenced applications require special procedures
actuated. to bleed the hydraulic system properly. The mounting
position of the master cylinder on the firewall traps air
in the rear portion of the cylinder. Before bleeding the
system, remove the master cylinder from the firewall
and position it so the reservoir end is higher than the
push rod end. This will enable air to escape from the rear
portion of the cylinders. Use only approved hydraulic
fluid recommended by the manufacturer.
For additional information, refer to Ford bulletin #93-12-19.

Plastic Straps
LB172 NO RELEASE
Vehicles: 1993-95 7.3- and 7.5-liter Ford F250,
F350 and F450 Super Duty
2. Do not change the position of the release bearing. Referenced vehicles were prone to no release, caused
by a defective hydraulic release system. To eliminate
Moving the bearing from its position may result in
leaks that may cause this condition, install an upgraded
damage to the seal and void the warranty. master cylinder and slave cylinder. These components
3. Be careful not to drop the slave unit or bend the must be installed together. Contact your distributor for
hydraulic lines. Inspect new slave cylinders for specific part numbers. A new tube kit, Ford part #F5TZ-
damage prior to installation. Inspect all protective 7A512-A, and pedal pivot shaft lever, Ford part#E7T2-
7A554-A, must be used with the upgraded parts.
For additional information, refer to Ford bulletin #95-4-9.

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LB176 SOLID FLYWHEEL OPTION CORRECT

Vehicles: 1987-94 7.3-liter Ford F-Series Trucks

The solid flywheel option is designed to replace the
original-equipment dual-mass flywheel. The solid Leaf Spring Clip
flywheel must be used with the clutch set designed for
it. It cannot be used with the original-equipment clutch
and disc. Release Bearing
When replacing the old components, use only the bolts Collar

supplied with the new unit. Tighten the bolts in a star

pattern. Torque the flywheel to crankshaft bolts to 45-49
ft-lb and the clutch bolts to 15-20 ft-lb. Thread sealant INCORRECT
is pre-applied to the flywheel to crankshaft bolts. The
pilot bearing included should be pressed in from the
transmission side of the flywheel. The factory backing
plate, located between the crank bolts and flywheel,
must be reused.

LB177 HARD PEDAL CONCERNS

Vehicles: 1985-94 Chevrolet/GMC C/K, G, R and
S/T Series, Blazer, Jimmy, Sonoma
Hard pedal and scraping noise while actuating the clutch
pedal may be caused by failure of the clutch pedal return
spring. Remove the return spring. It is not needed for
proper operation. LB180 DIAGNOSING SLIPPING AND
For additional information, refer to GM bulletin #46-73-03. CHATTER
Vehicles: Volkswagen Cabrio, Cabriolet, Golf, Jetta,
Rabbit, Scirocco
LB178 REPLACE SLAVE CYLINDER TO Slipping or chattering conditions result from oil
ELIMINATE HARD PEDAL/RELEASE contamination of the disc friction material. The clutch
PROBLEMS push oil seal (VW part #020 311 108A) is often the source
Vehicles: 1998-93 Ford Bronco, Explorer, F-Series, of the oil leak. Also inspect the push rod seal, the rear
Ranger; Mazda B2300, B3000, B4000, Navajo main engine seal and the transmission input shaft seals.
Hard pedal/release problems may result from leaks in Replace the push rod bushing (VW part #020 311 107C)
the internal seal of the slave cylinder. Replace the slave with a push rod seal.
cylinder with one that contains an upgraded seal to
prevent leakage.
For additional information, refer to Ford bulletin #97-22-17.
LB181 FLYWHEELS REQUIRE BALANCE
WEIGHTS
Vehicles: 1989-96 Chevrolet Corvette (not required for
LB179 RELEASE BEARING INSTALLATION Camaro or Firebird applications)
The release bearing fork/combination on many General Chevrolet Corvettes manufactured from 1989 to 1996
Motors applications makes it very easy to install the were equipped with a dual-mass flywheel, which cannot
parts incorrectly with the leaf spring clip of the fork be resurfaced and must be replaced.
above the bearing collar. Improper installation will cause The driveline in these vehicles is unusually sensitive to
slipping, hard pedal and release problems. Ensure the vibrations. For this reason, the flywheels are designed
leaf spring is installed under the bearing collar. to allow fine balancing of the engine and flywheel/clutch
assembly by adding additional balance weight(s).
When replacing the flywheel, the factory fine balance
on the engine must be maintained. To do this, remove
the existing flywheel and place it beside the new one so
both flywheels are in the same position relative to the
crankshaft dowel.
Install the same number of new balance weights in the
same positions as the original flywheel.
Install the crankshaft bolts with Loctite® 262 to prevent
oil leakage and torque all bolts to the specifications
listed below:
Flywheel to Crankshaft Bolt 74 ft-lb (100 Nm)
Clutch to Flywheel Bolt 30 ft-lb (41 Nm)

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LB182 SOLID FLYWHEEL OPTION LB189 REMOVE DOWEL PINS PRIOR TO

Vehicles: 1992-96 6.5-liter Chevrolet/GMC INSTALLATION
C/K1500-3500, P30/3500 Vehicles: 1994-97 7.3-liter Ford F-Series Trucks
The solid flywheel option is designed to replace the Remove the clutch-to-flywheel dowel pins prior to
original-equipment dual-mass flywheel. The solid installation. They are unnecessary because the clutch
flywheel must be used for the clutch set designed for it. is designed to center itself using the shoulder of the
It cannot be used with the original-equipment clutch and original-equipment mounting bolts. If the dowel pins
disc. are not removed, they will cause interference with the
When upgrading to a solid flywheel, use only the bolts clutch cover.
supplied with the new flywheel. Torque the flywheel When tightening the clutch, ensure you draw the
to crankshaft bolts in a star pattern to 65 ft-lb and the clutch down following the numbered pattern below.
clutch to flywheel bolts in a star pattern to 25 ft-lb. A By starting the sequence with the two locating holes
propshaft damper must also be installed. The purpose of (identified by the letter “L” stamped adjacent to the bolt
the damper is to balance the inertia of the engine with hole), the clutch will be centered to the flywheel bolt
the drivetrain and eliminate vibration. Two-wheel drive circle. It is important that the clutch be tightened in even
trucks equipped with a propshaft brake (all 15, 000-GVW increments, using only hand tools, to minimize distortion
models) do not require the installation of a damper, of the cover. The torque specification for the clutch
as the added mass of the brake balances engine and mounting bolts is 15 to 20 ft-lb.
drivetrain inertia values.
Failure to follow the recommended tightening sequence
For installation of the propshaft damper in two-wheel may result in clutch chatter and/or driveline vibration..
drive applications, GM part #15664906 is required. When ´
locating
installing the yoke damper nut, use Loctite® 242 on the 8 1 holes
nut threads and torque to 325 ft-lb (441 Nm).
For installation of the propshaft damper in four-
wheel drive applications, GM part #15635329 is
required. The damper is installed between the 6 3
transmission and the transfer case. The transmission
rear extension housing must be removed to install
the damper. When installing the retaining nut,
apply Loctite® 242 to the nut threads and torque to
325 ft-lb (441 Nm).

LB183 LUK FLYWHEEL MUST BE INSTALLED

Vehicles: 1999-02 7.3-liter Ford F-Series Trucks
The clutch set for the referenced vehicles contains
a clutch, disc and flywheel, engineered to install as 4 5
a matched set. Combining the original-equipment
flywheel with the clutch and disc in this set will result
in interference with the clutch fork. Discard the original
flywheel. locating´
2 7
holes
When replacing the old components, use only the bolts
supplied with the new unit. Tighten the bolts in a star
pattern. Torque flywheel to crankshaft bolts to 87-91
ft-lb, and the clutch bolts to 15-20 ft-lb. Thread sealant is
not required on the flywheel to crankshaft bolts.
The factory backing plate, located between the crank
bolts and flywheel, must be reused.

LB188 LUK SOLID FLYWHEEL OPTION

Vehicles: 1994-97 7.3-liter Ford F-Series Trucks
The solid flywheel option is designed to replace the
original-equipment dual-mass flywheel. The solid
flywheel must be used with the clutch set designed for
it. It cannot be used with the original-equipment clutch
and disc.
When replacing the old components, use only the bolts
supplied with the new unit. Tighten the bolts in a star
pattern. Torque flywheel to crankshaft bolts to 87-91 ft-lb,
and the clutch bolts to 15-20 ft-lb. Thread sealant is not
required on the flywheel to crankshaft bolts. The pilot
bearing should be pressed in from the transmission
side of the flywheel. The factory backing plate, located
between the crankbolts and flywheel, must be reused.

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LB190 HOW TO BLEED SLAVE CYLINDERS LB192 DO NOT LUBRICATE

WITHOUT BLEED SCREWS The release bearing and pre-lubricated internal slave
The slave cylinder for this application is manufactured cylinder are designed to operate without any additional
without a bleed screw to purge air. If the slave cylinder lubrication. Do not lubricate these parts during
has a gold allen screw, do not remove or loosen it. installation. Doing so may cause premature failure.
This set screw is not intended to be used for bleeding
purposes. The proper bleeding procedures for slave
cylinders without bleed screws follows. LB194 RELEASE BEARING INSTALLATION
1. Push the slave cylinder pushrod inward and
PROCEDURE
disconnect both bands of the retaining strap to The slave cylinder you remove from the vehicle will
enable the pushrod to fully extend. Do not cut or appear similar to one of the two original-equipment
discard the retaining strap. designs shown below.
2. Tilt the slave cylinder at a 45-degree angle. The
master cylinder line port should be facing upward
with the port at the high end of the slave. Fill the
slave cylinder with fresh, clean brake fluid.
3. Insert the master cylinder line into the slave cylinder
port. Lubricate the enclosed o-ring with brake fluid
and insert the retaining pin.
4. Hold the slave cylinder vertically with the pushrod
facing the ground. If this is not possible due to
the master cylinder line, position the slave as far This procedure provides instruction for bearing
vertically as possible without putting excessive load installation on slave cylinders that include a
on the master cylinder line. The slave cylinder must spring boot assembly and plastic spacer.
be lower than the master cylinder.
5. Remove the master cylinder reservoir cap.
Washers
6. Slowly push the slave cylinder pushrod into the slave
Retaining Ring
approximately one inch, watching for air bubbles
in the master cylinder reservoir. Air in the release
system should be purged after 10 to15 strokes of the
slave cylinder pushrod.
7. After all air is purged from the system, slowly push
the slave cylinder pushrod back into the slave and
reconnect the two bands of the retaining strap.
8. Install the slave cylinder with the retaining strap in
place. The retaining strap will break free with the first
stroke of the pedal. Press down on the bearing to remove the retaining
Note: The plastic cover over the end of the pushrod must be ring and two washers. Discard the ring and washers.
retained; it acts as a lubricant between the pushrod and the
fork. Removing the cover can cause a no-release condition.
Bearing

LB191 FLYWHEEL-TO-DISC INTERFERENCE Spring-Boot

Vehicles: 1997-00 5.7-liter Chevrolet/GMC Full-Size Truck Assembly
and 1996 with New Venture Transmission
Plastic Spacer
The clearance between the disc damper and the flywheel-
to crankshaft bolt heads on this application is minimal.
Slave Cylinder
When the original disc is removed, contact marks may be
evident on the disc coil springs, indicating interference.
Flywheel resurfacing increases this interference, causing
noise and release problems.
This clutch set includes a low
profile disc, designed to
accommodate light flywheel
resurfacing, along with a Remove the bearing, spring boot assembly and
depth gage to verify plastic spacer.
clearance. After resurfacing,
place the flywheel on a flat
surface and insert a flywheel-to-crankshaft bolt. Place the
gage on the flywheel friction surface and center it over the
bolt head. There should be a visible air gap between the
gage and the bolt head. If the gage touches the bolt head,
the flywheel is too thin to fit the disc without interference,
and a new flywheel must be installed.

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Spring
LB197 IMPORTANT INSTALLATION
INFORMATION
Rubber Boot Vehicles: BMWs with Self-adjusting Clutches
The self-adjusting clutches for some BMW applications
include a shipping plate, which must not be removed
prior to installation. If the plate is removed prematurely,
the clutch will self-adjust and become completely
unusable. Removal or tampering with the shipping plate
will void the warranty. Follow the instructions below for
proper installation.
Remove the slave cylinder spring from the Installation of these clutch sets requires a reusable, two-
boot assembly, discarding the rubber boot, piece tool, which must be purchased separately.
release bearing and plastic spacer.
Contact your distributor for these tools:

Retaining Ring

Seat the new release Press down on the

bearing assembly on the bearing to install the new
slave cylinder spring and retaining ring, included Detach the threaded
install the assembly on in the clutch set. bolt and insert the
the slave cylinder. body of the installation
tool into the flywheel
pilot bearing.

The slave cylinder is now

ready for installation.

LB195 13-INCH FLYWHEEL UPGRADE FOR

DODGE CUMMINS TURBO DIESELS
Vehicles: 1988-03 5-Speeds
The 13-inch flywheel upgrade is engineered specifically
Install the clutch and disc. Insert a 14 mm
for Cummins-powered Dodge trucks. It features the
hex-head wrench into the clutch shipping
same factory-installed flywheel design used in 2001 and
plate center hole and turn it counter-
newer models.
clockwise to remove. Discard the plate.
Attention to detail, thorough examination and
replacement of all worn clutch system components can
eliminate immediate off-the-lift problems and prevent Thread the bolt into
premature clutch failure. Follow the manufacturers’ the installation tool
guidelines for clutch removal and installation. body and remove the
Reinstall the starter using the spacer plate and mounting tool. Complete the
bolts provided. Place the spacer plate between the clutch installation
engine block and starter mounting surfaces, and torque according to vehicle
the bolts to 30-34 ft-lb. Install the flywheel and torque the m a n u f a c t u r e r ’s
mounting bolts to 99-103 ft-lb. Clean the contact surfaces specifications.
of the flywheel with a non-residue, alcohol-based
cleaner to remove any grease or contaminants. Install
the clutch using the eight bolts provided in the kit. Torque
the bolts to 15-20 ft-lb.

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LB199 CLUTCH INSTALLATION PROCEDURE LB207 NOISE AND PREMATURE CLUTCH

Vehicles: 2001-05 8.1- and 6.6-liter Chevrolet Silverado WEAR
and GMC Sierra Trucks Vehicles: 2002-04 Ford Focus SVT
These vehicles feature a sealed hydraulic release system Referenced applications may exhibit signs of premature
and a concentric slave cylinder (CSC), which does not clutch wear or produce a clunk or rattle noise while the
include a bleeder valve. Prior to disconnecting the slave vehicle is in neutral and the clutch pedal is disengaged.
cylinder, the release system hydraulic pressure must The noise diminishes when the pedal is actuated. These
be relieved to prevent clutch release problems. Follow problems may be caused by alignment issues in the
the procedures below and refer to the vehicle service clutch, disc, dual-mass flywheel or transaxle.
manual for detailed clutch replacement instructions.
If the vehicle exhibits either of the these conditions,
Unbolt the transmission from the engine block and inspect the following:
rotate it 90° to expose the CSC. Remove fluid from the
• Transaxle fluid level – fill if low.
clutch master cylinder reservoir until the level is halfway
between MIN and MAX. Push the CSC toward the • Slave cylinder for leaks – replace if necessary.
transmission until it bottoms out. Locate and disconnect • Release bearing for smooth operation – replace if
the slave cylinder “quick connect” hydraulic fitting on rough.
the outside of the bell housing.
• Bearing retainer to ensure the bearing slides
Install the new clutch. Reconnect the slave cylinder smoothly - polish scoring with emery paper.
“quick connect” fitting. Bolt the transmission to the
engine. Inside the vehicle cab, actuate the clutch pedal • Input shaft splines for wear or damage – polish
three full strokes. Top off the clutch master cylinder small scoring or burrs with fine-grit emery paper or
reservoir to theMAX line with fresh fluid. crocus cloth.
• Alignment of dowel pins with the engine and
transaxle – replace if damaged.
LB204 LUK FLYWHEEL MUST BE USED • Corresponding dowel pin holes – if elongated to
Vehicles: 1999-02 7.3-liter Ford F-Series Trucks more than .040’’ out of round, the transaxle must be
Referenced clutch sets are engineered for use only replaced.
with LuK flywheel #LFW140 (LuK #LFW140). Prior to • Separator plates, located between engine and
ordering or installing these sets, you must verify that transaxle, for damage or warping – replace if
the vehicle contains a LuK flywheel. If these sets are necessary.
installed with the original-equipment flywheel - or any
other manufacturer’s flywheel - interference will result, • Crankshaft flange for contamination or rust – clean if
the clutch will not function properly, and there is a necessary.
possibility of complete and catastrophic failure of the Install a complete clutch set, which includes a revised
system. clutch, disc and dual-mass flywheel. You must install all
of the new components because they are incompatible
with those in the vehicle.
Torque all bolts in a star pattern to these specifications:
• Flywheel mounting bolts to 83 ft-lb
• Clutch mounting bolts to 21 ft-lb
If the vehicle is not already
equipped with a LuK flywheel, order • Transaxle mounting bolts to 35 ft-lb
the Luk Clutch Set, which includes For additional information, refer to Ford bulletin #04-21-19.
a new flywheel.

To verify the vehicle contains the correct flywheel,

LB209 SQUEAKING NOISE
Vehicles: 2004-06 Ford Rangers
remove the flywheel from the vehicle and check the
crankshaft side for the LuK insignia and the part number Referenced applications may produce a squeaking noise
LFW140. If these are not found, order the clutch set that while the clutch pedal is actuated or released. The noise
includes a new flywheel. also may be detectable with the engine off while cycling
the clutch pedal. If you confirm the noise is coming from
After removing the flywheel, it must be resurfaced; the bell housing, replace the slave cylinder with LuK part
failure to resurface the flywheel voids the warranty. #LSC003 or revised Ford part # 6L5Z-7A508-AA.
Install the resurfaced flywheel, reusing the factory-
installed backing plate, located between the For additional information, refer to Ford bulletin #06-23-13.
crankshaft bolts and flywheel. Tighten flywheel-
to-crankshaft bolts in a star pattern to a torque of
87-91 ft-lb. Thread sealant is not required. Tighten the
clutch bolts in a star pattern to a torque of 15-20 ft-lb.

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ENGLISH TECHNICAL BULLETINS

LB212 INTERCHANGEABLE CLUTCH SETS LB228 NISSAN & INFINITI DMF

Vehicles: 2005-06 1.9-liter Volkswagen Jetta TDI with INSTALLATION
Engine Designation BRM Vehicles: 2002-12 Nissan, Infiniti
Both LuK and Sachs manufactured complete clutch The vehicles equipped with this dual mass flywheel have
sets for the above-referenced applications. Either a crankshaft tone ring built into the flywheel. The dual
manufacturer’s system can replace the other, but only if mass flywheel is not indexed on the crankshaft and can
all three components are replaced. DO NOT mix Sachs be installed different ways.
components with LuK components. The Sachs version
When installed incorrectly, the vehicle may not start,
may contain a defect, leading to burnt disc friction
have a check engine light, and the engine will not rev
material and clutch pressure plate heat damage. Always
past 2,000 RPM.
replace the dual-mass flywheel if it shows signs of heat
damage; it cannot be resurfaced. When removing a dual mass flywheel from the vehicles
listed above, it is recommended to make your own
indexing marks on the flywheel and crankshaft. When
LB227 PEDAL VIBRATION AND NOISE installing the new flywheel transfer your marks from the
AFTER CLUTCH INSTALL old flywheel to the new flywheel to ease installation and
Some vehicles may exhibit a rattle, chirp, squeak, and or assure proper indexing.
pedal vibration after a new clutch is installed. Insufficient If you have already removed the flywheel and did not
pre-load on the release bearing may be the cause. The make any indexing marks, follow this procedure for
original self adjusting cable and plastic quadrant are proper installation:
known to wear and fail over time. The correction is to 1. With the flywheel removed look for the alignment
replace the cable and quadrant with a new upgraded, dowel pin hole on the end of the crankshaft.
adjustable cable and all aluminum quadrant. This will
allow for proper release bearing pre-load to be set. 2. On the new flywheel find the same alignment dowel
pin hole.
Installation of new cable and quadrant :
This can be done by finding the locating hole and
1. Remove the old cable from the plastic quadrant notch on the front side of the flywheel.(see Figure 2)
and from the transmission. When you have located the notch and hole on the
2. Remove the three cotter pins or hitch pins and front side, flip the flywheel over and find the same
washers from the quadrant and ratcheting paw hole that goes all the way through the back side.
assembly. Keep the pins and washers for use Then look at Figures 1-3 and find the dowel pin hole.
during reinstallation.
3. When both have been located align the two holes
3. With the pins removed, slide the plastic quadrant and torque the flywheel to the proper specifications.
and ratcheting paw off the mounting studs. On
some models the ratcheting paw assembly may 4. See Figures 1-3 to aid in locating the correct dowel
have to be cut in half to remove due to the heater pin holes.
box being in the way. Figure 1

4. Install new aluminum quadrant onto pedal

assembly by sliding onto the studs.
5. Install the washers and the pins onto the studs.
6. Install the new cable assembly onto the quadrant.
7. Install the cable onto the clutch fork and adjust the
cable to proper pre-load.
8. After test driving the vehicle recheck for proper
cable adjustment.
Figure 2

Figure 3

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TECHNICAL BULLETINS ENGLISH

LB229 OVER-CENTER SPRINGS AND SOFT LB232 DODGE RAM DUAL MASS FLYWHEEL
CLUTCH PEDALS TO SOLID FLYWHEEL CONVERSION
”Over-center” or release assist springs as they are Vehicles: 1-24-05 production date to 2010
sometimes called, may result in a very soft pedal 5.9L / 6.7L Cummins Dodge Ram with G-56 transmission
when a coil spring clutch is replaced with a diaphragm
spring clutch. designed to reduce the higher pedal
effort associated with coil spring clutches, over-center LuK # LuK Global #
springs may overcompensate when a diaphragm spring RepSet ®
05-184 632 2164 000
is installed. The results can include a very soft clutch
pedal, and in some cases, a clutch pedal which will go Flywheel LFW184 416 0228 100
to the floor- and stay there. To eliminate these problems, *LuK now offers a Dual Mass Flywheel to Solid Flywheel
remove the over-center springs. conversion for the 1-24-2005 production date to 2010
5.9L/6.7L Cummins Dodge Ram with G-56 transmission.

LB230 ABRUPT ENGAGEMENT OF You must use a new LuK RepSet® and new LuK solid
flywheel together! The LuK RepSet and LuK flywheel
HEAVY-DUTY CLUTCHES are manufactured as a complete paired unit! If your
Some Clutch kits contain heavy duty discs made of vehicle currently has a solid flywheel conversion of
Cerametallic friction material. This material normally another brand manufacturer when replacing the clutch
results in abrupt engagement of the clutch and some assembly with LuK RepSet 05-184, you will need to use
degree of clutch chatter. Please advise the owner of the the matching LuK solid flywheel.
vehicle that this characteristic is normal before you sell
or install a clutch kit containing a cerametallic disc. When replacing your clutch system with the complete
LuK dual mass flywheel conversion kit, you will find
that the LuK solid flywheel is thicker than your OEM
flywheel. It is also made from nodular iron. This design
benefit eliminates the need for the OE flex plate and
helps withstand higher temperatures and clamp loads.
Additionally, you are able to reuse the factory OEM
hydraulics, so no need to replace release system and fork.
* Please be sure to replace the flywheel mounting bolts
with the bolts included with the flywheel.
* Due to the dual mass flywheel to solid flywheel
conversion, some gear rattle may occur. This is a normal
characteristic due to the lack of shock absorption from
the new solid flywheel.
Flywheel to crank torque specs: 85 ft. lbs
Clutch/pressure plate to flywheel torque specs: 40 ft. lbs.

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