Warning: Clutch wear dust that settles on clutch components contains asbestos, which is hazardous to health. Do not blow off this dust with compressed air or inhale it. Do not remove dust with gasoline or gasoline-based solvents. Asbestos dust should be washed off with brake cleaner into a tray. After wiping the clutch components dry with a rag, place the rag and used cleaner in a labeled, closed container.
Removal
1. Remove the transmission as described in part A Chapter 7.
2. Using pliers, pull back the ends of the bearing retaining clip to release the fork.
3. Remove the bearing from the clutch housing. Be careful not to lose the retaining spring.
4. Fix the center part of the bearing and turn the outer part until pressure appears. If it does not turn smoothly or makes noise. The bearing must be replaced.
Fork mounted on an axle
5. Check the release fork for excessive wear. If the fork needs to be replaced and space permits, remove the spring pins from the fork and axle using a small drift and hammer (see illustration). If there is not enough space to use a hammer, use a tool such as the puller shown (see illustration). Discard the spring pins, slide the axle out of the clutch basket, and remove the fork, spring, and spacers (see illustration).
4.5a. If space permits, remove the spring pins using a small drift and hammer - use new pins for reassembly
4.5b. If there is no space to remove the pins through the shaft, they must be removed using a special puller - this illustration shows a correctly installed Mitsubishi puller (MD998807)
The material was borrowed from the website (www.mitsubishiman.ru)
4.5s. After installing the MD998807 puller, turn the head clockwise to remove the spring pin
4.5d. Details of the fork mounted on the axle and the bearing. 1. Spring clamp, 2. Clutch release bearing, 3. Spring pin, 4. Release fork shaft, 5. Return spring, 6. Release fork, 7. Bushing, 8. Bushing
6. Lubricate the release fork shaft hole in the clutch basket with high temperature grease (see illustration), partially insert the shaft into the clutch basket and install the spacers, spring and fork in place. Continue to push the shaft through the parts and align the spring pin holes. Insert the new spring pins into place with the pin slots facing up (see illustration).
4.6a. Apply high temperature grease to the areas shown
4.6b. Insert the locking pins with the slots facing up
7. Lightly lubricate the ends of the release fork with a small amount of high-temperature grease (see illustration). Pack the groove inside the release bearing with the same grease (see illustration) and install it against the release fork.
4.7a. Apply high temperature grease to the indicated areas
4.7b. Pack the inner groove of the release bearing with high temperature grease
8. Reinstall the bearing retaining clamp. Make sure the clamp fits securely into the groove and that the ends fit correctly into the release fork.
9. Install the gearbox.
Ball joint mounted fork
10. Check for excessive wear on the ends of the release fork. Replace the fork if necessary. Pull the fork toward the rubber boot and disconnect it from the ball joint (see illustration).
4.10. Details of the release fork mounted on the ball joint and the bearing. 1. Spring clamp, 2. Clutch release bearing, 3. Release fork, 4. Ball joint, 5. Release fork boot
11. Before installing the fork, apply a small amount of grease to all metal contact surfaces.
12. Install in the reverse order. Check that the ends of the release fork clamp are hooked onto the ball joint.