Relates to: Magna TP, TN, TS, TR, Mitsubishi 3000GT, Diamante, FTO, Gallant, GTO. Or Kit Nos. R1221N, R318N, R1452N, R363N, R1077N, R320N, R281N.

Background: The following concerns can occur with the above applications. These are not due to the Clutch Kit. It is necessary to rectify these issues with the vehicle to achieve correct clutch operation.

1. Rough or Notchy Pedal Feel This is caused by wear in the release bearing guide. As the Magna has a compact bell housing design, there is nowhere for the clutch dust to go. As the clutch plate wears, the dust builds up on the release bearing guide and with the movement of the release bearing, the dust causes severe wear to the guide. The wear on this guide causes the bearing to become notchy or in severe cases, jam in the work area.

2. Clutch Non-Release or Difficult Gear Selection After a New Clutch Kit is Installed

Non-release in Magnas is caused by a number of reasons. The main three are:- a) The Magna clutch uses a short bearing travel to release the clutch (approx. 6mm). This is

because of the compact design of the bell housing. Any wear in the release mechanism reduces the bearing travel sufficiently to cause non release. The main concern is usually at the pivot ball and clutch fork ball seat. When replacing the clutch, inspect and replace these parts if any wear is noted. Alternatively, fitting a 2mm spacer behind the pivot ball will counteract the wear in the components.

b) Where the clutch master cylinder push rod has been adjusted to give the clutch release bearing more travel. Incorrect adjustment can result in negating the self-adjusting mechanism and/or over-stoking of the diaphragm which will foul the clutch plate making gear selection difficult. It is important to ensure the clutch pedal adjustment is kept to specifications as shown below.

c) Clutch dust or facing material left in the bell housing. It is necessary to thoroughly clean out the gear box housing before re-fitting. Dirt, oil and facing material from the old clutch can become lodged under the new cover assembly, causing non-release. Dirt and oil can contaminate the clutch plate facings causing shudder and slipping.

Pedal Play – 6 to 13mm Clutch Engaged – 173 to 178mm Clutch Disengaged – 55mm or more

3. Flywheel Re-Machining It is important when re-machining flywheels to keep the relative distance between the friction face and cover assembly bolt up surface the same as the original “Flywheel Step”. I.e. always machine the same amount off the cover bolt up surface as is machined off the friction face.

Vehicle Specific Clutch Kit Installation Notes

TBC01