Manual gearbox - flywheel housing and clutch cover

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Flywheel Housing    
Ill. No. Part No. Description Qty. Rqd. Remarks
1 22G999 FLYWHEEL HOUSING 1 1959-68, 3 synchro gearbox.
  DAM3165 FLYWHEEL HOUSING 1 1968-79, 4 synchro gearbox.
  DAM6259 FLYWHEEL HOUSING 1 1979-92, 4 synchro gearbox, not 1275.
2 DAM6257 FLYWHEEL HOUSING 1 1979-91, 4 synchro gearbox, 1275 carburetter.
  DAM3161 FLYWHEEL HOUSING 1 1979-91, 4 synchro gearbox, 1275 carburetter.
  TRD10015 FLYWHEEL HOUSING, with hole for crank sensor 1 1991 on, 4 synchro gearbox, 1275 injection and carburetter.
3 88G302 BEARING, idler gear (1.004" ext. dia.) 1 1959-68, 3 synchro gearbox.
  13H7848 BEARING, idler gear (1 1/16" ext. dia., 3/4" int. dia.) 1 1968-79, 4 synchro gearbox.
  AHU1707 BEARING, idler gear (1 3/8" ext. dia., 7/8" int. dia.) 1 1979 on, 4 synchro gearbox.
  DAM3745 BEARING, idler gear, special, with sleeve (1 3/8" ext. dia., 3/4" int. dia.) 1 For use, see note below.
4 LCG10001 BLANKING PLATE, crank sensor hole  1 1992-94, 1275 carburetter.
5 FS105101 SCREW, blanking plate to flywheel housing 2 1992-94, 1275 carburetter.
         
Interchangeability of flywheel housings:    
For 1959-68 models (3 synchro gearbox), none of the later 4 synchro flywheel housings can be used in place of the original.
For 1968-79 models (not 1275), flywheel housing DAM6259 may be used, so long as the special idler bearing with sleeve DAM3745 is also fitted.
For 1968-79 models (1275 only), flywheel housing DAM6257 may be used, so long as the special idler bearing with sleeve DAM3745 is also fitted.
For 1979-91 models (1275 carburetter), flywheel housing TRD10015 may be used, so long as the crank sensor hole blanking plate LCG10001 and two screws FS105101 are also fitted.  Additionally, TRD10015 may also be used for 1968-79 1275 models so long as the blanking plate and screws are fitted along with the special idler bearing and sleeve DAM3745.
         
These notes show how to use later (therefore hopefully still available) flywheel housings on earlier 4 synchro power units.  They rely on the original idler gear being retained... if you're not sure what's original on the car for its year, to be safe you may have to dust off your vernier caliper and deduce (i) the external diameter of the idler gear bearing required (measure the bearing location in the flywheel housing) and (ii) the internal diameter required (measure the idler gear shaft diameter).  Having done so, you should be able to find a bearing size above to suit your purposes.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
6 13H2934 OIL SEAL, clutch (primary gear oil seal) 1 All carburetter models.
  LUF10005 OIL SEAL, clutch (primary gear oil seal) 1 All injection models.
7 DAM2821 SHIELD, oil seal protection 1 1982 on; all Verto clutch models.
8 AAU8424 BEARING, first motion shaft 1  
9 2A3643 CIRCLIP, bearing to flywheel housing 1  
10 CCN110 CIRCLIP, bearing to first motion shaft 1  
11 TRK100300EVA GASKET, flywheel housing to cylinder block/gearbox 1 Genuine.  Superior sealing material. 
  GUG705563GM GASKET, flywheel housing to cylinder block/gearbox 1 Alternative.
12 18G8086 LOCK TAB KIT, clutch 1 Includes lock tabs for strap and flywheel securing screws, plus lock tabs for flywheel housing screws.\
13 22A1762 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.
14 22A1761 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.
15 2A3521 LOCK TAB, flywheel housing attachment 1 Included in clutch lock tab kit.
16 22A1241 LOCK TAB, flywheel housing attachment 1 1968 on (4 synchro gearbox); included in clutch lock tab kit.
17 BH605141 BOLT, long, flywheel housing attachment 3  
  DAM7758 BOLT, flanged, long, flywheel housing attachment 3 Alternative.
18 LWZ305 WASHER, locking 3  
19 SH605081 SCREW, short, flywheel housing attachment 3  
  DAM7753 BOLT, flanged, short, flywheel housing attachment 3 Alternative.
20 FNZ505 NUT, flywheel housing attachment 9  
21 LWZ305 WASHER, locking 4  
22 22A1299 PLATE, dowel retaining 1 1968 on (4 synchro gearbox).
         
For certain markets or on certain models during the 1960s, the starter solenoid was fixed to a bracket attached to the flywheel housing:
Ill. No. Part No. Description Qty. Rqd. Remarks
23 12A369 BRACKET, starter solenoid to flywheel housing 1 Not Cooper S models.
  12G326 BRACKET, starter solenoid to flywheel housing 1 Cooper S models.
24 SH505051 SCREW, bracket to flywheel housing 2  
25 LWZ305 WASHER, locking 2  
         
Clutch Cover and Clutch Release Mechanism    
1959-82, Coil Spring or Diaphragm Clutch    
Ill. No. Part No. Description Qty. Rqd. Remarks
26 88G300 COVER, clutch, with timing hole 1  
27 2A3635 COVER, timing hole 1  
28 SH604041 SCREW, timing hole cover to clutch cover 2  
29 LWZ304 WASHER, locking 2  
30 53K146 SCREW, clutch cover to flywheel housing 8  
  DAM7755 BOLT, flanged head, clutch cover to flywheel housing 8  
31 LWZ305 WASHER, locking 8  
32 22A180 PLUNGER, clutch release  1 Release bearing secures by press-fit.
33 DAM1955 PLUNGER, clutch release  1 Alternative; release bearing secures with clip.
34 DAM2413 CLIP, release bearing to plunger 1 Use with DAM1955 plunger.
35 22A427 NUT, clutch release stop 1  
36 NT610041 NUT, locking clutch release stop nut 1  
The very earliest cars from 1959-60 were originally fitted with a plunger with an integral (non-adjustable) stop.  This may be replaced by either of the plungers listed above, together with a 22A427 stop nut and NT610041 lock nut.
         
Ill. No. Part No. Description Qty. Rqd. Remarks
37 22A2204 LEVER, clutch release 1  
38 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1  
39 PWZ106 WASHER, plain 1  
40 ZPS307 SPLIT PIN 1  
41 SH604141 SCREW, lever adjusting 1  
42 FNZ604 NUT, locking adjusting screw 1  
43 CLZ518 CLEVIS PIN, lever to slave cylinder push rod 1  
44 PWZ105 WASHER, plain 1  
45 ZPS306 SPLIT PIN 1  
46 1G5999 SPRING, clutch release lever 1  
47 2A3601 ANCHOR, spring, clutch release lever end 1  
48 2A3600 ANCHOR, spring, slave cylinder end 1  
         
1982 On, Verto Clutch    
Ill. No. Part No. Description Qty. Rqd. Remarks
49 AHU1068 COVER, clutch, with timing hole 1 1982-85; with inertia starter.
  AHU1106 COVER, clutch, without timing hole 1 1985 on; with pre-engaged starter.
50 2A3635 COVER, timing hole 1 1982-85.
51 SH604041 SCREW, timing hole cover to clutch cover 2 1982-85.
52 LWZ304 WASHER, locking 2 1982-85.
53 53K146 SCREW, clutch cover to flywheel housing 8  
  DAM7755 BOLT, flanged head, clutch cover to flywheel housing 8  
54 LWZ305 WASHER, locking 8  
An extra screw used to secure a Verto clutch cover is the long screw securing the slave cylinder bracket (please see Clutch Pedal and Hydraulics section).
Ill. No. Part No. Description Qty. Rqd. Remarks
55 DAM5353 PLUNGER, clutch release 1  
56 AAU2866 O RING, release bearing 1  
57 22A427 NUT, clutch release stop 1  
58 NT610041 NUT, locking clutch release stop nut 1  
59 DAM5355 LEVER, clutch release 1  
60 CLZ628 CLEVIS PIN, lever pivot in clutch cover 1  
61 PWZ106 WASHER, plain 1  
62 ZPS307 SPLIT PIN 1  
63 SH604141 SCREW, lever adjusting 1  
64 CLZ518 CLEVIS PIN, lever to slave cylinder push rod 1  
65 PWZ105 WASHER, plain 1  
66 ZPS306 SPLIT PIN 1  
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