TSK48 INSTRUCTIONS

Joseph Cox |

Installation Procedure – PDM Clutch Sleeve TSK48 Repair Kit

Tools & Materials Needed:

  • Solvent, carburetor cleaner, or brake cleaner

  • Sandpaper, emery cloth, or Scotch-Brite™ pad

  • #2 lithium grease

  • Loctite (optional)

  • Basic hand tools

Procedure:

  1. Remove Original Components

    • Remove the original throw-out bearing and clutch fork from the transmission.

  2. Clean Transmission Snout

    • Thoroughly clean the transmission snout using solvent, carburetor cleaner, or brake cleaner to remove any debris or grease.

  3. Smooth the Snout Surface

    • Use sandpaper, emery cloth, or a Scotch-Brite™ pad to smooth out any burrs or imperfections on the snout.

    • Clean again to ensure no abrasive residue remains.

  4. Install the Repair Sleeve

    • Carefully slide the repair sleeve over the transmission snout.

    • Ensure the back of the sleeve seats firmly against the transmission case.

    • A light tap on the shoulder of the sleeve may be necessary to seat it fully.

    • Do not tap on the leading edge of the sleeve—this can damage it or cause the throw-out bearing to bind.

  5. Secure the Sleeve

    • Tighten the set screws evenly.

    • Do not overtighten, as this may crack the snout or deform the sleeve.

    • Applying Loctite to the set screw threads is recommended but not mandatory.

  6. Lubricate

    • Apply #2 lithium grease to:

      • The outer surface of the sleeve

      • The groove inside the new throw-out bearing

      • The pivot ball on the transmission

  7. Install Throw-Out Bearing and Fork

    • Attach the throw-out bearing to the clutch fork by lightly squeezing the retainer clip and slipping it into the back of the fork.

    • Reinstall the fork and throw-out bearing assembly into the transmission.

  8. Final Step

    • Apply the provided label to the right strut tower to indicate the installation of the repair kit.