WARRANTY

English

If you are the original consumer, Mantic Engineering Pty Ltd ACN 150 735 514 (“Mantic”) warrants its products to be free from defects in material and workmanship for a period of 90 days from the date of purchase or 6,000 miles (9650 km), whichever occurs earlier. If a Mantic product is found to be properly installed, maintained and operated in accordance with all applicable instructions and specifications, then, Mantic at its sole option will replace or repair the defective product, or refund the purchase price to the original consumer. The following are NOT covered by this warranty: 1. Normal wear and tear, including wear and tear of any friction materials forming the surface between the clutch disk and pressure plate or used as a component of the product; 2. Any defect or damage caused by a collision or other accident; 3. Any defect or damage caused by the failure to store, handle, install, assemble, maintain or use the product in accordance with Mantic’s instructions or specifications, including but not limited to: (a) use of the product in breach of the SFI Specification 1.1 including but not limited to use of the product in an engine with a rotational speed of over 7000 RPM’s; (b) modification of the product by the customer in any way; or (c) installation of the product in a vehicle that is not in full compliance with the instructions and specifications of the manufacturer of that vehicle; 4. Any defect or damage arising directly or indirectly as a result of racing or competing in the vehicle in which the product is installed; 5. Any defect or damage arising directly or indirectly as a result of the failure to use and install an appropriate scatter shield; or 6. Any damage to other products caused by a Mantic product; 7. The cost of any rental vehicles or equipment pending the repair or replacement of a defective product; or 8. Any costs associated with making a claim under this warranty, including but not limited to the cost of removing and returning the product, and the cost of reinstalling the product after it has been repaired or replaced. All such costs shall be the responsibility of the consumer. This warranty will be VOID automatically if in Mantic’s reasonable opinion the product has been subject to any unreasonable use, misuse, negligence, fire, or accident; or the product has been modified, repaired or dismantled without Mantic’s prior written authorization; or any Mantic part has been replaced with a non-Mantic part. Mantic reserves the right in its sole discretion to inspect, evaluate and test the purportedly defective product in any way deemed appropriate by Mantic, and then make the final decision as to whether the product in fact is faulty or defective in material or workmanship. This is our exclusive written warranty. We make no other express warranties, nor is anyone else authorized to make any express warranties on our behalf. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Mantic shall not be liable for special, incidental, or consequential damages of any kind, including but not limited to incidental or consequential labor costs, installation charges, telephone charges, or transportation charges, in connection with the replacement or repair of any defective products. Upon discovering a purported defect that you believe is covered by this warranty, you must immediately return the product to Mantic or an authorized seller of the product, at your own cost, together with a detailed written description of the purported defect and proof of the place and date of the original purchase. To obtain warranty service return to the original place of purchase and/or contact Mantic Engineering PTY LTD via email on [email protected].

WARNING

Mantic products are designed for high performance and are inherently dangerous. If not installed, maintained and used in compliance with all applicable instructions and specifications, Mantic products can cause property damage, serious bodily injury and death. By purchasing and using this Mantic product, you are acknowledging that you understand the dangers, hazards and perils in using these high performance products, and you voluntarily elect to accept all risks arising directly or indirectly from any improper installation, maintenance or use of any Mantic product.” Some states do not permit disclaimers or limitations for implied warranties or incidental or consequential damages, so the disclaimers and limitations in this warranty statement may not apply to you. Your legal rights may vary from state to state.

GARANTIA

Español

Si usted es el consumidor original, Mantic Engineering Pty Ltd ACN 150 735 514 (“Mantic”) garantiza que sus productos están libres de defectos en materiales y mano de obra, durante un período de 90 días, a partir de la fecha de compra o 6,000 millas (9650 km), lo que ocurra primero. Si se encuentra que un producto Mantic está apropiadamente instalado, mantenido y operado de acuerdo con todas las instrucciones y especificaciones aplicables, Mantic a su exclusivo criterio, reemplazará o reparará el producto defectuoso, o reembolsará el precio de compra al consumidor original. Lo siguiente NO está cubierto por esta garantía: 1. Uso y desgaste normal, incluyendo el desgaste de los materiales que forman la superficie de fricción entre el disco de embrague y la placa de presión, o usado como un componente del producto; 2. Cualquier defecto o daño causado por una colisión u otro accidente; 3. Cualquier defecto o daño causado por error de almacenamiento, manejo, instalación, ensamble, mantenimiento o utilización del producto de acuerdo con las instrucciones de Mantic o las especificaciones, incluyendo, pero no limitado a: (a) el uso del producto en violación de la especificación SFI 1.1, incluyendo, pero no limitado al uso del producto en un motor con una velocidad de rotación de más de 7000 RPM, (b) la modificación del producto por el cliente en cualquier manera, o (c) la instalación del producto en un vehículo que no está en plena conformidad con las instrucciones y especificaciones del fabricante de dicho vehículo; 4. Cualquier defecto o daño que surja directa o indirectamente como resultado de carreras o competencias en el vehículo en el que está instalado el producto; 5. Cualquier defecto o daño que surja directa o indirectamente como resultado de la falla de la utilización e instalación de un escudo de dispersión adecuado, o 6. Cualquier daño a otros productos causado por un producto Mantic; 7. El costo de cualquier vehículo de alquiler o equipo en espera de reparación o reemplazo de un producto defectuoso, o 8. Cualquier costo asociado con hacer un reclamo bajo esta garantía, incluyendo pero no limitado, al costo de remover y devolver el producto, y el costo de volver a instalar el producto después de que haya sido reparado o reemplazado. Todos estos costos serán responsabilidad del consumidor. Esta garantía será NULA automáticamente si en la opinión razonable de Mantic el producto ha sido objeto de cualquier uso no razonable, mal uso, negligencia, incendio o accidente; o que el producto haya sido modificado, reparado o desmontado sin la autorización previa por escrito de Mantic; o cualquier parte de Mantic haya sido sustituida por una parte que no sea de Mantic. Mantic reserva el derecho a su sola discreción, de inspeccionar, evaluar y probar el producto supuestamente defectuoso, en cualquier forma que se estime adecuado por Mantic, y luego tomar la decisión final en cuanto a si el producto es defectuoso, de hecho, o si hay defectos de materiales o mano de obra. Esta es nuestra garantía exclusiva por escrito. Nosotros no hacemos ninguna otra garantía expresa, ni cualquier otra persona está autorizada para hacer ninguna garantía expresa de nuestra parte. ESTA GARANTÍA SE DA EN LUGAR DE CUALQUIER OTRA GARANTÍA, EXPRESA O IMPLÍCITA, INCLUYENDO GARANTÍAS DE COMERCIALIZACIÓN SIN LIMITACIÓN,Y APTITUD PARA UN PROPÓSITO PARTICULAR. Mantic no será responsable por daños especiales, incidentales o consecuentes de cualquier tipo, incluyendo, pero no limitado a los costos laborales indirectos o consecuentes, gastos de instalación, gastos de teléfono, o gastos de transporte, en relación con la sustitución o reparación de cualquier producto defectuoso. Al descubrir un supuesto defecto que usted cree que está cubierto por esta garantía, usted debe inmediatamente devolver el producto a Mantic o a un vendedor autorizado de los productos, a su propio costo, junto con una descripción detallada por escrito del supuesto defecto y prueba del lugar y la fecha de la compra original. Para obtener Servicio de garantía, regrese al lugar original de compra y / o póngase en contacto con Mantic Engineering PTY LTD en electrónico en [email protected].

ADVERTENCIA

“Los productos Mantic están diseñados para alto rendimiento y son inherentemente peligrosos. Si no son instalados, mantenidos y utilizados de acuerdo con todas las instrucciones y especificaciones aplicables, los productos Mantic pueden causar daños materiales, lesiones corporales graves y muerte. Al comprar y usar este producto Mantic, usted está reconociendo que entiende los peligros y los riesgos en el uso de estos productos de alto rendimiento, y que voluntariamente decide aceptar todos los riesgos derivados directa o indirectamente de cualquier instalación incorrecta, de mantenimiento, o uso de cualquier producto Mantic.” Algunos estados no permiten exenciones o limitaciones de garantías implícitas o daños incidentales o consecuentes, por lo que las renuncias y limitaciones de esta Declaración de garantía, pueden no aplicar para usted. Sus derechos legales pueden variar de estado a estado.

CONTENTS

GMH Concentric Slave Cylinder bearing replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 “Direct fit” Clutch kit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Driveline Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fitting a non specific Mantic Track Series clutch: (9000 / 7000 / 5000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Non Mantic Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Release Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Application: Mantic Street series (Australia Only) Ford Falcon XR8/ GT/GT-P (54 Litre V8) 5 and 6 Speed Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation Instructions for Mantic BA/BF/FG (Australia Only) Falcon 6cyl Turbo Clutch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GMH Concentric Slave Cylinder Bearing Replacement Relates to: Mantic Street series kits – GM (Chevrolet / Holden) When replacing the Concentric Slave Cylinder (CSC) bearing it is critical to ensure that the used bearing does not leave behind a seal in the bore of the CSC. The seal is adhered to the bearing during manufacturing but after prolonged use has been seen to come free. If this occurs and a new bearing is installed whilst the old seal is still in the bore, the clutch system will not exhibit appropriate characteristics. Pedal feel and possible loss of clamp load can occur. It is critical to inspect the bore of the cylinder for such a seal.

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Step 1:

When transmission is removed from vehicle remove the bearing and spring.

Removal of bearing from CSC assembly

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Step 2:

When bearing has been removed from CSC assembly inspect the back of the bearing. If Seal is present proceed as normal with new bearing installation. (Refer 2) Shows used bearing with no seal. (Refer 3) Shows a new bearing with seal.

(Figure 2) No Seal

(Figure 2)

(Figure 3)

(Figure 3) Blue Seal present Note: Seals range in colour from blue, white and black ..................................................................................................................

Step 3:

If no seal is on the back of the bearing proceed to inspect the bore of the CSC. (Refer 4) Shows the seal at the bottom of the CSC bore. Note: In many situations the seal will be difficult to see (Figure 4) White coloured due to grease concealing its presence. seal at bottom of CSC bore

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Step 4:

With the aid of a thin flathead screwdriver remove the seal. Proceed as normal with new bearing installation.

(Figure 5) Removal of white seal

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“Direct fit” Clutch Kit Installation 1. Unpack all of the clutch kit components and check that all parts are supplied. 2. Check clutch discs slide freely on the transmission input shaft. Remove all labels and clean the friction surfaces of the flywheel, pressure plate and intermediate plates i.e. using a cleaning fluid such as paint thinners or acetone. 3. Insert the cover assembly mounting bolts through the flywheel from the engine side of the flywheel and ensure the heads of the bolts fit snugly into the groove on the engine side of the flywheel. (Refer Pic 1&2) 4. Bolt the flywheel to the engine crankshaft with the bolts supplied. Use a suitable Loctite (Loctite 272) on the threads and tighten to the manufacturer’s specification.

Pic 1

Pic 2

Pic 3

Pic 4

Pic 5

Pic 6

5. Slide the drive blocks onto the clutch mounting bolts supplied, making sure the heads of the bolts are still in the groove on the back of the flywheel. (To check put your finger through the hole in the flywheel opposite each bolt and feel that the head is in place) (Refer Pic 4) 6. Mount the clutch disc with the part number suffix “-F/X” onto the flywheel with the side marked “flywheel Side” against the flywheel and insert an alignment tool through the clutch disc spline. (Refer Pic 5) 7. Assemble the intermediate plate onto the drive blocks as shown. (Refer Pic 7: MOI Intermediate plate shown) Note: Care must be taken when handling the intermediate plate spring clips as they are factory set for release. If they are damaged in any way the clutch may not operate as designed. The Foam Packing must be removed just before installation. (Refer Pic 8: MOI Plus kits do not have spring clips on the Intermediate plate). Make sure the heads of the bolts are still in the groove on the back of the flywheel. 8. For Triple Plate Kits Only - Mount the Clutch Disc with the Part number suffix “C” over the alignment tool and onto the intermediate plate with the side marked “flywheel Side” towards the flywheel. Slide second intermediate plate over the drive blocks, and ensure the heads of the bolts are still in the groove on the back of the flywheel. 9. Mount the Clutch Disc with the Part number suffix “-P” over the alignment tool and onto the intermediate plate with the side marked “pressure plate Side” against the Cover or pressure plate.

Remove foam packaging from the spring clips before installation.

10. Slide the cover assembly over the clutch mounting bolts (Refer Pic 9: MOI Plus cover shown) and make sure the Drive blocks are sitting on the correct mounting surface of the flywheel and cover assembly (Refer Pic 10&11) and that all of the heads of the bolts are still in the groove on the back of the flywheel. 11. Place the supplied lock washers (failure to use the supplied lock washers may result in the nuts working loose and the clutch failing) and nuts over the clutch mounting bolts and tighten each by hand, until the heads have seated correctly in the groove on the back of the flywheel. Ensure the drive blocks have seated correctly on the flywheel and Cover, (Refer Pic 10&11 i.e. not sitting up on the machined step that positions the drive blocks). Tighten each nut one half a turn at a time, always tightening the nut diagonally opposite the previously tightened nut. The final torque for the nuts is 33Nm. When the nuts are tightened the fingers of the diaphragm should now be even. (No variation of the heights of each diaphragm finger). If there is variation of over 1mm the cover has not been fitted correctly and should be loosened and checked as per the procedure above.

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Pic 7

Pic 8

Pic 9

Pic 10

Cover slid over bolts.

Ensure blocks do not ride up on the step on the flywheel or cover during assembly.

Pic 11

Driveline Alignment Before fitting your Mantic clutch kit it is important to check the vehicle for driveline alignment. Poor alignment will cause premature failure of your clutch. The standard size clutch with sprung clutch discs can handle the typical alignment of a production vehicle, however smaller and more particularly solid center clutch discs require more accurate alignment to obtain the maximum life and performance expected from this style of clutch kit. Therefore it is critical that the alignment of the driveline be checked prior to fitment of your Mantic clutch kit. The bell housing must be checked for concentricity and parallelism. This can be done using a dial indicator mounted on the crankshaft. The maximum run out allowable is 0.15mm (0.0059”) T.I.R (Total Indicator Reading) and the maximum out of parallelism is 0.15mm (0.0059”) T.I.R.

Concentricity Check

Parallelism Check

If misalignment is present you will need to find the cause. • • • •

Inspect all dowels and dowel holes for condition. Clean all mating surfaces. Inspect block flange for damage. Inspect the block flange for out of parallelism.

REMEMBER - IF MISALIGNMENT IS PRESENT, FITTING A NEW CLUTCH KIT WILL NOT FIX THE CAUSE OF THE PROBLEM AND THE MISALIGNMENT WILL QUICKLY DESTROY THE NEW CLUTCH.

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Fitting a Non Specific Mantic Track Series Clutch: (9000 / 7000 / 5000 Series) Mantic non specific kits are supplied without bolts due to the varying threads that may already be in use on existing flywheels, and differing lengths required. Any bolts used must be a minimum Grade #8 tensile strength, and tightened to 33Nm. Clutches are designed to be mounted with M8 X 1.25 (5/16 UNF) bolts (8 x 9000 kits, 6 x 5000, 6 x 7000 kits). Under no circumstances should the locating holes in the cover or drive blocks be enlarged. All kits are supplied with special washers for use under the bolts.

Flywheel design considerations:

When installing a Mantic kit that is not a “Direct Fit Kit” i.e. it does not come with a purpose fit flywheel, it is important that the flywheel being made conforms to the dimensions in the sketch below as a minimum to ensure correct fitment.

Fitting to an existing 7.25” / 5.5” flywheel: (7000, 5000 series)

(It is essential that the working surface of the flywheel be ground, or the flywheel replaced if cracks are present.) 1. When using an existing 7.25” or 5.5” flywheel, the PCD (Pitched Circle Diameter) of the Mantic 7000 / 5000 clutch is the same as used currently by most clutch companies. 2. When using these flywheels it is possible to bolt the clutch to the flywheel from the clutch (out) side into the existing threaded holes. 3. Ensure that the bolts are the correct length not to foul, that they are #Grade 8 (minimum) tensile strength, and the supplied washers are used under the head of each bolt. Tension the clutch to 33Nm. 4. The only modification needed in this instance is to ensure that there is a -1.5mm deep groove cut into the flat surface of the clutch working area to locate the drive blocks. (See diagram page 9.) This groove is essential for the operation of the clutch to ensure that the height of the clutch is to correct specification. 5. Check and adjust pedal throw / bearing travel as specified below. A pedal stop may need to be fitted.

Fitting to a non Mantic flywheel: (9000, 7000, 5000 series) 1. Re drill the flywheel with the correct mounting bolt pattern and PCD (Pitched Circle Diameter). This should be done by a specialist engineer to ensure absolute accuracy. 2. Machine a -1.5mm deep groove on the working surface of the flywheel to locate the clutch drive blocks as per the dimensions in the diagram below. This groove is essential for the operation of the clutch to ensure that the heights of the clutch are to correct specification. 3. If mounting the clutch with bolts coming from the rear of the flywheel, a groove must be machined into the rear of the flywheel to locate the bolt heads. (Refer page 9) 4. Ensure that the bolts are the correct length not to foul, that they are #Grade 8 (minimum) tensile strength, and the supplied washers are used under the nut of each bolt. Tension the bolts to 33Nm. 5. If mounting the clutch with bolts coming from the front of the flywheel, it is vital that there be sufficient material for the threads to ensure the structural integrity of the flywheel. 6. Ensure that there is a -1.5mm deep groove cut into the flat surface of the clutch working area as per the diagram on page 9. This groove is essential for the operation of the clutch to ensure that the heights of the clutch are to correct specification. 7. Check and adjust pedal throw / bearing travel as specified below. A pedal stop may need to be fitted.

Warning

Modifications to and/or production of a suitable flywheel for use with Mantic products should only be carried out by qualified individuals. Mantic accepts no responsability for flywheels which are not produced by Mantic. Flywheel specifications must be appropriate for use in the installed application.

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Non Mantic Flywheels Flywheel design considerations: When installing a Mantic kit that is not a “Direct Fit Kit” i.e. it does not come with a purpose fit flywheel, it is important that the flywheel being made conforms to the dimensions in the sketch below as a minimum to ensure correct fitment. When modifying an existing flywheel to the above specifications, it is critical that there be sufficient strength remaining to maintain the structural integrity of the flywheel. Mantic accepts no responsibility for the subsequent failure of such a modified flywheel. Do not use with cast iron flywheels.

Release Bearings Release bearing installation: It is important that the correct length, travel and diameter release bearing/concentric slave cylinder/ hydraulic release bearing is installed with your new Mantic clutch to ensure correct actuation. 1. Calculate the distance from the installed clutch diaphragm finger tip to the mounting base of the release bearing. 2. Measure the fully compressed height of the release mechanism. 3. The measurement in 1. Must be 4 to 6mm more than the measurement in 2. (This is to allow for wear of the friction material i.e. as the clutch disc(s) wear the diaphragm finger height increases). If it is more than 6mm, spacers must be placed under the CSC, or adjust the throwout mechanism to achieve this measurement. If it is less than 4mm, a CSC that is shorter or increase your bell housing length with a spacer. 4. The bearing travel must be within the maximum and minimum figures shown in the table below. If the travel is higher than the maximum the diaphragm can be over stroked and cause non release or damage the diaphragm. If the travel is below the minimum the clutch will not release fully making shifting gears difficult or not possible. 5. The bearing contact diameter and travel required is shown in the table below. Mantic Kit type

9000 Racing Series (Cushioned discs) 9000 Racing Series (Non Cushioned discs) 7000 Series 5000 Series

Contact Face Type

Bearing Travel Max

Bearing Travel Min

Bearing Contact Dia Max

Bearing Contact Dia Min

Flat

11.5mm

11.0mm

68mm

47mm

Flat

7mm

5mm

68mm

47mm

Radial Radial

7mm 7mm

5mm 5mm

50mm 42mm

46mm 38mm

Note: It may be necessary to use a pedal stop to prevent over stroking. Clutch height / release load Specifications Clutch type Release Load lbs/kg

9000 2 disc 7000 3 disc 7000 2 disc 5000 3 disc 5000 2 disc

275lbs/125kg 440lbs/200kg 440lbs/200kg 440lbs/200kg 440lbs/200kg

Diaphragm finger height

Overall Height

Cover to flywheel bolt tor que

2.81in / 71.5mm 2.39in / 60.6mm 1.12in / 28.4mm 1.15in / 29.1mm 1.44 in / 36.7mm

3.21in / 81.5mm 3.02in / 76.8mm 1.74in / 44.3mm 1.85in / 47mm 2.15in / 54.6mm

24 ft lb / 33Nm 24 ft lb / 33Nm 24 ft lb / 33Nm 24 ft lb / 33Nm 24 ft lb / 33Nm

in/mm

in/mm

lb.ft / Nm

Height is measured from flywheel drive block mounting surface. Direct fit to most 5.5in / 7.25in flywheel bolt patterns. F/W must be modified Cover to flywheel bolts must be minimum grade #8. M8 x 1.25 or 5/16 UNF must be used. Refer to fitting instructions on the previous page. Non Mantic flywheels for custom F/W specifications.

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Mantic Street Series Ford Falcon XR8/ GT/GT-P (5.4 Litre V8) 5 and 6 Speed Manual FOR AUSTRALIA ONLY In achieving increased torque capacity this performance clutch kit is designed to utilize one of two spacers provided. A 4mm Spacer to suit 5 speed transmission and 8mm spacer to suit 6 speed transmission. The spacers are designed to correctly position the Concentric Slave Cylinder (CSC) for the respective applications. The following procedure explains the installation of the spacer.

Procedure: 1. Remove the transmission from the vehicle as per the OEM’s procedure. 2. Remove the CSC from the input shaft of the transmission by removing the 2 CSC mounting bolts. 3. Replace CSC with new bearing assembly from the kit. Note: OEM’s recommend that the CSC be replaced with every new clutch kit installation. 4. The Mantic kit should contain a 4mm & 8mm thick zinc plated spacer. The 4mm spacer suits the 5 speed transmission and the 8mm spacer suits the 6 speed transmission. 5. Place the spacer in the back of the CSC. Align the bolt holes of the CSC with the spacer and put the bolts through the aligning holes. Refer picture above.

4mm or 8mm spacer

CSC bolts

Bolts must align through the CSC, the spacer and secure into tapped bell housing holes.

Warning: The 6 speed comes with a factory fitted 2mm spacer. Remove 2MM spacer and replace with 8mm spacer from kit. 6. Put the CSC back over the transmission input shaft and slide it back to its home position. 7. Secure CSC in place by tightening to CSC bolts back to OEM torque specifications. Note: If using the 8mm Spacer please use the supplied bolts and washers. 8. Install other clutch kit components as per OEM’s specifications.

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Installation Instructions Mantic BA/BF/FG Falcon 6cyl Turbo FOR AUSTRALIA ONLY 1. Unpack all of the clutch kit components and check that all parts are supplied. 2. Check clutch discs slide freely on the transmission input shaft. Remove all labels and clean the friction surfaces of the flywheel, pressure plate and intermediate plates, using a cleaning fluid such as paint thinners or acetone. 3. Bolt the flywheel to the engine crankshaft with genuine bolts. Use a suitable Loctite (Loctite 272) or similar on the threads and tighten to the manufacturer’s specification (Refer Pic 1). 4. Place the supplied lock washers onto the mounting bolts and insert two of Pic 1 the bolts (Refer Pic 2) through the cover assembly directly opposite each other. Place the cover assembly face down on the assembly bench. Place the drive blocks over the mounting bolts and mount the pressure plate as shown on the drive blocks (Refer Pic 3). (failure to use the supplied lock washers may result in the nuts working loose and the clutch failing) 5. Place the pressure plate (Refer Pic 4) then the clutch disc with the suffix “P/X” onto the pressure plate (Refer Pic 5), ensuring that the side marked “pressure plate” faces towards the pressure plate / cover. 6. Remove the foam packing from the spring clips on the intermediate plate (Refer Pic 6). Assemble the intermediate plate onto the drive blocks as Pic 4 shown (Refer Pic 7). Care must be taken when handling the intermediate plate spring clips as they are factory set for release. If they are damaged in any way the clutch may not operate as designed. 9000 Series MOI Plus kits do not have spring clips on the intermediate plate. 7. Select the clutch disc with the suffix “F/X”. Place the disc in position on the aligning tool with the side marked “flywheel side” facing upwards (towards the flywheel) (Refer Pic 8). 8. Insert the clutch aligning tool into the assembled clutch. Now place the assembled clutch onto the flywheel (Refer Pic 9) taking care to insert the Pic 7 front of the aligning tool into the spigot bearing. Start the bolts into the threaded holes in the flywheel by hand and leave loose. 9. Position a drive block into the cut out in the pressure and intermediate plates, and insert bolt through and start the thread by hand. Leave loose, repeat until all bolts and blocks are in position (Refer Pic 10). 10. Tighten the bolts in a cross hatch pattern. Note: As the bolts are tightened, continually check that the drive blocks are correctly positioned on the locating step in the flywheel, and the similar locating step in the clutch cover. Failure to have the blocks correctly located will result in the clutch failing to Pic 10 operate. Finally tighten the bolts to 33Nm. 11. Remove the Clutch aligning tools.

Pic 2

Pic 3

Pic 5

Pic 6

Pic 8

Pic 9

Pic 11

Pic 12

IMPORTANT: Ensure the drive blocks have seated correctly on the flywheel and cover (Refer Pic 11 & 12) not sitting up on the machined step that positions the drive blocks (Refer Pic 13). Tighten each bolt one half a turn at a time, always tightening the bolt diagonally opposite the previously tightened bolt. The final torque for the bolts is 33Nm. When the bolts are tightened the fingers of the diaphragm should now be even. (No variation of the heights of each diaphragm finger). If there is variation of over 1mm the cover has not been fitted correctly and should be loosened and checked as per the procedure above.

Pic 13

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Mantic Engineering Pty Ltd. For further technical advice email [email protected]