Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 How to install a new clutch pack

Time to put the new clutch pack onto the engine.



First clean up the flywheel bolts


Attach the Flywheel to the engine shaft
80 ft lbs of torque on the bolts





We have a tool that can hold the flywheel from turning as you torque the bolts down.
It's a Snap On Tool A-144 Flywheel holder



Next up is the pressure plate - it has a label on which side faces the flywheel.







****Next is a critical Step **** (sorry no picture)
Using the pilot shaft ailment tool to center the clutch plate splines on the crankshaft.
Note: Without it being aligned to the pilot shaft correctly when going into the pilot shaft, it could damage the previous installed pilot shaft bushing!




Metric Clutch Alignment Tool need to do the job right



Torque pressure plate to flywheel at 25 ft lbs

the pilot shaft bushing that was installed with a small press before it was installed into the compensator part of the engine.





When bolting on the transmission tunnel:
No Lock tight to be used on these bolts
Be sure to use a small lock washers
Torque to 28 ft lbs

Interesting. Looks like there was copperslip or similar on the flywheel bolts.

My flywheel holding tool is a bent valve! Works a treat and very cheap...

My clutch centring tool is a handled rod and a selection of screw on and slide on bits. Never met a clutch I could not adapt it to and it's had plenty of use over the years.

My last clutch alignment tool was a Snap-On strong bar handle and insulating tape.

What about the story i hear of putting in the clutch the other way around in a 3 wheeler

When finishing up the install the only issue we had to work through was bleeding and building up pressure in the new cultch slave line. We used a brake bleeding system that built up some sucking vacuum pressure to help bleed the line to get the brake fluid down into the cutch slave. We also found a tiny piece if dirt right in the end of the bleeder that didn't help either.

Up and running now.

After talking to MORGAN regarding clutch pricing, i am puzzled why you change the flywheel at the same time.
http://www.moss-europe.co.uk/ sell clutches and flywheels for Mazda MX5`s at quite a saving over the price of a local dealer, if anyone is interested.

From what I gather the clutch used is NOT a Mazda. The Miata clutch assembly with their lightened flywheel looks nothing like the pictures JV has posted.

I think that Morgan has used the Miata trans, but has used their own flywheel and clutch setup. I think JV referenced Volvo as Morgan's possible source for the assembly he installed.

So I doubt that Miata parts are going to work. I could be wrong though...

The flywheel and clutch pack is Morgan designed and sold only thru Morgan service department.
The only Mazda part is the sealed case and everything behind the the Volvo sourced clutch slave unit. We thought it looked like a BMW motorcycle clutch setup of some kind and seeing that Morgan does have a relationship with BMW it could well be.