Manual gearbox - flywheel housing and clutch cover

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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Manual gearbox - flywheel housing and clutch cover

CIRCLIP-1st MOTION BEARING TO SHAFT

BEARING-IDLER GEAR-4 SYNCHRO '79 ON- A+(1 3/8''EXT 7/8'' INT)

COVER-CLUTCH-NO TIMING HOLE-VERTO-PRE ENGAGED STARTER

COVER-CLUTCH-WITH TIMING HOLE-VERTO-INERTIA STARTER

BEARING-1st MOTION SHAFT-NOSE

O RING-CLUTCH RELEASE BEARING RETAINING-VERTO

CLUTCH COVER WITH TIMIING HOLE

USE: SH505081

CIRCLIP 1st MOTION BEARING TO FLYWHEEL HOUSING

PLATE-BLANKING-TIMING HOLE IN CLUTCH COVER

ANCHOR TAB- SPRING-CLUTCH RELEASE LEVER END

ANCHOR TAB-SPRING-CLUTCH LEVER RETURN-SLAVE END

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