*Dimension to be obtained by
adjusting the throwout lever.
FIG 5:1 Clutch assembly longitudinal section (new
500, 500D sedan and early station wagon)
5:2 Removal and installation
To remove the clutch unit from the vehicle proceed as
follows:
1 Remove the engine (Chapter 1) or separate the gear-
box from the engine as described in Chapter 6.
2 Remove the six screws and washers that secure the
clutch cover to the flywheel and gently ease the cover
assembly from the location dowels in the flywheel and
lift away. This will also free the driven plate.
3 Carefully clean the driven plate and clutch cover using a
compressed air jet.
4 To refit the clutch cover assembly to the flywheel
ensure that the driven plate is assembled the correct
way round as shown in FIG 5 :1 and place the cover
onto the flywheel using the locating dowels.
5 To ensure that the driven plate is correctly centred use
Fiat pilot A.62023 (see FIG 5 : 5) or a suitably sized
mandrel. Tighten the clutch mounting screws diagonally
a turn at a time to ensure correct location of the cover
onto the flywheel face. Finally, tighten to a torque
wrench setting of 5.8 to 7.2 Ib ft.
5 :3 Dismantling and inspection of clutch cover
New 500, 500D sedan and early 500 station wagon :
To dismantle the clutch cover assembly proceed as
follows:
60
To assemble the clutch cover assembly proceed as
follows:
1 Place the pressure plate complete with carrier ring bolts
and springs on Fiat fixture 62038 (see FIG 5:2).
2 Fit the six pressure springs in their respective seats on
the pressure plate. Insert the cups on the springs and
replace the cover.
3 Compress the clutch cover, continually checking that
the withdrawal lever supporting bolts are properly
guided into their holes in the cover. Onto the bolts, fit
the three withdrawal levers with their relevant nuts and
washers.
4 Replace the carrier ring on the levers and hook up the
retaining springs.
5 :4 Assembly and adjustment
New 500 sedan
1 Place the clutch cover assembly on Fiat fixture A.62038
as shown in FIG 5 :6 and lock the cover using the three
T-handles provided.
2 Release the withdrawal lever carrier ring springs and lift
away the ring.
3 Unscrew the withdrawal lever fixing nuts on the bolts
and lift out the levers and washers. Gradually slacken
the three T-handles so relieving the pressure of the
clutch springs. Remove the clutch cover, springs and
lever mounting bolts. Carefully mark all the components
to ensure that they are assembled correctly so ensuring
that correct balance of the clutch unit is obtained.
Inspection:
Thoroughly clean all parts using a compressed air jet
and proceed as follows:
1 Thoroughly check the springs for signs of overheating
causing loss of tension and compare the effective length
of the springs which when fitted new should have a
length of .9646 inch under a load of not less than 43 Ib.
If the spring length is less than the recommended
dimension fit a complete new set of springs.
2 The length of the withdrawal lever carrier ring retaining
springs should be checked which under a normal clutch
load should be .7677 inch whilst the length'of the
expanded spring under a load of 4.85 ± .44 Ib should
be 1.1811 inch. If the springs show sign of heating or
weakening a new set should be fitted.
3 Check the withdrawal levers and their bolts for exces-
sive wear and fit new parts as necessary.
4 Inspect the pressure plate for an excessively ridged sur-
face or signs of cracking. If the ridges are not too severe
the face may be refaced by turning on a centre lathe.
Also inspect the flywheel friction surface which may
also be refaced providing that the ridges are not too
severe.
5 Whenever the clutch driven plate linings are worn a new
driven plate should be fitted.
6 Inspect the clutch shaft splines and these should not
have a lengthwise clearance in excess of .0039 inch and
side clearance of .0118 inch with respect to the driven
plate hub. Ensure that the driven plate slides easily on
the clutch shaft protruding from the rear of the gearbox
differential unit as any plate drag may be the cause of
difficulty in gear selection.
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