SAFARI

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10
CLUTCH
4. SPECIFICATIONS
4A. CLUTCH DISC (Fig.3)
Outside diameter 228 +1 mm.
Inside diameter 150 + 1.5 mm.
_ 1.0
Thickness of clutch disc 9.3 ± 0.3 mm.
with new lining under
570 kg load ‘A’
Maximum permissible 0.5 mm.
out of perpendicularity
of each lining surface of
clutch disc w.r.t. spline
axis at 223 mm diameter
Maximum permissible 25 gm-cm.
imbalance of clutch disc
Cushioning of clutch disc 0.9/1.2 mm
Spline size of clutch disc A10 x 23 x 29 (DIN 5464)
Total friction area 463
(both sides)
4B. CLUTCH PRESSURE PLATE ASSEMBLY
(Fig.4)
Height of pressure plate 34.5 mm.
housing ‘A’ max.
Height of diaphragm 28.2 ± 1 mm.
tip from cover mounting
surface ‘B’
Max. permissible imbalance 20 gm-cm.
of pressure plate assembly
Max. permissible face run 0.5 mm.
out of release bearing
contact surface of diaphragm
Clamp load on clutch disc 570 to 660 kg.
Diaphragm release load Max. 210 kg.
(with Disc)
Tip travel, 'C' 8 +1 mm.
Max tip travel after use of disk, 'D' max.8.5 mm.
Pressure plate lift for min. 1.8 mm.
release travel 8+1 mm
4C. CLUTCH ACTUATION HYDRAULIC SYSTEM
Clutch master cylinder 19.05 mm.
diameter
Clutch master cylinder 34.5 mm.
stroke
Slave cylinder diameter 23.81 mm.
Slave cylinder stroke 52.0 mm.
5. REMOVAL OF CLUTCH FROM VEHICLE
l Place chokes on wheels to prevent movement
of vehicle.
l Disconnect battery and electrical connections of
the starter motor.
l Loosen mounting bolts and remove starter motor.
l Unlock and remove U/J cross mounting strip
screws at gear box end. Disconnect propeller shaft
from gear box and suspend it sideways suitably.
l Loosen and remove clutch slave cylinder
mounting nuts and tie it suitably.
l Pull out reverse indicator switch cable connector.
l Disconnect speedo cable
l Disconnect and remove gear box along with clutch
housing from engine (Follow the procedure given
in gear box group for removal of gear box
assembly from vehicle)
l Remove clutch release bearing with sleeve.
l Pull out clutch release fork from spring clip.
l As a safety measure, support clutch pressure
plate and clutch disc with mandrel 2654 5890 25
01. Unscrew sixmounting bolts evenly (alternately
and crosswise) in small steps.
l Remove clutch pressure plate assembly and
clutch disc along with the mandrel.