Transmission, Manual

Double-Disc Clutch Adjustment

Double-Disc Clutch Adjustment

Put the double-disc clutch in and...

It grinds trying to put it into gear.

I read the "Devek" instructions beforehand and don't quite understand how to make the evaluation of position. On my '80, I can't see the front of the intermediate plate or the front side of the forks. I tried to eyeball placing the forks equidistant from the plate when closed, but, again, could see the front side of the forks.

Someone please explain how to adjust this! (Painful detail appreciated)

'80 Euro S

I'll give it a shot, since I just did mine a couple of weeks ago. While on your back looking up at the clutch pack, you are looking that each cluch disc has the same gap from the intermediate plate.

1. You've got to make sure the clutch is disengaged, or put another way, the clutch fork is in the same position it would be if you pushed down on the clutch pedal. 'Disengaged' meaning the clutch discs are not held by the pressure plate. I used a carpenter's clamp to move the clutch fork back (simulating depressing the pedal) to achieve this.

2. When the clutch is free, you now want to focus on the intermediate clutch plate. Use a strong worklight, and move the front clutch disc (the one right behind the flywheel) TOWARD the flywheel. You can use a screwdriver, or the tip of your index finger to make sure the disc is against the flywheel. When you do this, there should be a small air gap (where your finger is now poked, or screwdriver blade) between that clutch disc and the face of the intermediate clutch plate.

3. Now, do the same measuring with your finger or screwdrive on the clutch disc that is on the other side of the intermediate clutch plate. That would be the disc between the pressure plate and the intermediate plate. You are now pushing the disc against the pressure plate, and the gap should be the same as the disc that's on the other side of the intermediate plate (between the intermediate plate and the flywheel).

4. On your car, one of the clutch discs is too close to the intermediate plate. The way this is adjusted is by moving the intermediate plate either toward the engine or toward the back of the car. You realize we are only talking mm's here. Rotate the engine by hand to get access to one of the three adjusters. Using a flat blade screwdriver, find the copper colored adjuster. Just to make sure: it's maybe an inch wide and 1/8" thick. You can get the screwdriver blade under one side at a time. It's like prying on either side of a 'T'. You should be able to see the intermediate plate move very slightly following your moving of the adjuster. Make sure both sides of the 'T' have been moved the same amount. Rotate the engine so that the other two adjusters receive the same attention.

5. Now, recheck the clutch disc gaps to make sure they are where they should be - exactly same air gap on both sides of the intermediate plate. If they aren't the same, go back and readjust the 'T's to get it as close as you can. It took me about three attempts.

I hope this description helps. It wasn't clear to me before actually doing the work how the adjusters worked or how to measure the gap. But it's one of those jobs that makes perfect sense once you've done it.

JP Rodkey
79 Euro

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