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Mitsubishi pajero 1992 turbo diesel 4cyl - clutch disk replacement

According to recent advice I need a new clutch disk is this a big job? Where can I obtain an owner's repair manual for my vehicle - and will this enable me to repair my vehicle myself?

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This job isn't one for the faint hearted - yes you do need some pretty special tools the main one being a transmission jack - its pretty heavy work otherwise a socket set and some basic knowledge.
but here's is a posting I recently made:
I am currently replacing the clutch plate, pressure plate and thrust bearing on a 1996 Mitsubishi pajero gen-II 6g74 5-spd
I found loads of information on unbolting and un-plugging the electric's etc. what I didn't find was information about separating the engine and transmission.
The thrust bearing is held in place by a cir-clip behind the pressure plate, the bearing fork is near imposable to access unless to two are separated.


note: I think it would've been best to do this when removing the hydraulic cylinder that moves the clutch fork as I had to re-bolt up the engine.


Here is how to do it !!
1: remove the two rubber inspection covers (one will be around the clutch fork) mine being r/h drive the fork is on the left-side, these are located either side of the gear box.
- Looking through the inspection ports you will see - thrust bearing, thrust bearing fork which is attached to the bearing via clips, back of pressure plate, gearbox input shaft .
2: you will need two long flat head screw drivers

3: you want to insert these between the thrust bearing and collar via the inspection ports to release the cir-clip

4: the thrust bearing and fork should now move freely on the splined shaft.

Still having problems ?
looking through the inspection holes - the collar shouldn't be visible (it looks like a spline)
- if it is !! you will need to move this further in to the pressure plate as the cir-clip wont have room to release behind the pressure plate.
- the point you are trying to insert the screw drivers into is between the collar and bearing (not the collar and pressure plate)
I was able to disengage the cir-clip for the trust bearing on the new pressure plate (on the bench) with a ball joint removal tool by a applying pressure to one side of the collar only - ( I don't think you can do this with the transmission in place as the thrust bearing fork gets in the way)
once removed - you will be able to separate the transmission and engine, unbolt the pressure plate, replace the clutch plate, unbolt the 10mm retaining bolt for the clutch fork which is located inside of the bell housing - knock up into the bell housing the frost plug this allows for the pin holding the fork to be removed (I did this by wiggling the fork back n forth and putting a piece of welding wire part way through the 10mm hole and pulling out through the frost plug hole).
hope this all helps someone...good luck

Posted on Apr 03, 2010

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