Spitfire1974 » Restoration » Gearbox and Clutch » Clutch

email Dave Braun at dave@dbraun99.com (click here)

The clutch system is pretty straight forward as far as hydraulic systems go. Of course, now that I've found my OD gearbox, and a later single rail one at that, I have to replace at least the clutch disc to match the splines, from 10 on the three rail box, to twenty on the single rail box. The original throw out bearing was 0.755 thick, the replacement only 0.645. I was concerned about losing throw, so I elected to go with the old one, which spins smoothly.

Clutch master and fasteners	Clutch slave cylinder on gearbox	Clutch pressure plate held on with allen screws	Clutch removed 01	Clutch removed 02
Old gasket on bell housing	Cleaning off gasket from Gearbox	Driving out clutch pivot pin	Clutch lever and backside of bearing	Mating bell housing with gearbox 01
Mating bell housing with gearbox 02	The lower bolt needs a copper washer to seal in the gearbox fluid. I annealed this one so that it will make a good seal.	Clutch line cleaned up and ready for installation	The pushrod holes were elongated from wear. Welded up the elongated side and ground the weld down.	Repairing the holes in the clutch push rod (2)
After the repair was very close with the round file, ran a 5/16 drill through the opening to clean it up and make them parallel.	Girling clutch cylinder and repair kit. The kit looks NOS. I've already honed the cylinder, cleaned the gook out of the reservoir, and polished the piston.	Piston seals and valves (1)	Piston seals and valves (2)	Piston seals and valves (3)
Lid and new gasket	Finished Clutch Master Cylinder. Notice the weld on the pushrod clevis holes, which then got a round file to take them back to standard size.	Clutch MC installed	Balancing the clutch and flywheel (2)	Balancing the clutch and flywheel (3)
Flywheel side	Balanced pressure plate and new clutch disk	Clutch Disk alignment	Installing pressure plate (1)	Installing pressure plate (2)
Installing pressure plate (4)	New clutch bearing and throwout lever pins	Old throwout bearing parts	Comparing wear in old bushes to new bushes (1)	Old and new throwout bearings (1)
Old and new throwout bearings (2)	This is the new throw out bearing. It is 0.645 thick, compared to the original 0.755 thick unit. The old unit is very smooth, but a touch stiffer. Because the hydraulics must take up the slack in the extra 0.11 throw, it will remove some of the tolerance for wear in the pins, even though I have removed as much slack from the system as I could. I ended up removing the new throw out bearing and reinstalling the old, thicker original one.	Tapping out pivot pin retainer	Pin stays in without epoxy	Lubricated clutch slave rod
Installed old throw out bearing (1)	Bench filling slave cylinder	Fitting slave cylinder in bracket as far as possible note crack	Installed old throw out bearing (2)	Filling Clutch MC with DOT 5
Bleeding Clutch

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