Clutch component locations
1. Transmission; 2. Clutch housing; 3. Fiction disc; 4. Flywheel; 5. Release bearing
Removal
1. Remove the transmission (Section 7).
2. Apply alignment marks to the pressure plate and flywheel so that they can be installed in the same position later.
3. When removing the pressure plate, hold the friction disc with a special tool or a screwdriver handle.
4. Lock the flywheel ring gear and evenly loosen the pressure plate mounting bolts, turning them one turn in a diagonal sequence to prevent the cover from deforming.
5. Remove the pressure and friction discs.
6. Carefully, without touching the surface of the linings, separate the friction disc.
7. Remove the return spring from the clutch release fork hook, turn the release lever and remove the release bearing.
Remove the release bearing
8. Remove the clutch release fork bolt and remove the fork assembly with the lever.
Inspection
9. Remove dust from the clutch housing using an electric vacuum cleaner or a clean cloth. Do not use compressed air for this, as you may inhale dust, which is hazardous to your health as the dust contains asbestos.
10. Inspect the pressure plate for damage and wear of the diaphragm spring, scratches and discoloration (indicates overheating) rubbing surface, as well as damage and deformation of the cover. Replace the pressure plate with a new unit if there is any doubt about its condition.
11. Inspect the flywheel surface for signs of uneven wear, which indicates improper installation or damage to the friction disc springs. Check for burns, grooves, cracks and other damage. A flywheel with a large number of nicks and grooves must be re-ground on a machine. Shallow scratches can be removed from the flywheel surface using fine-grain sandpaper.
12. Inspect the clutch friction linings for signs of contamination with oil, grease, etc. and replace the disc with a new one if such contamination is detected. Check the linings for wear by measuring the distance between the rivet head and the lining surface. Replace the disc with a new one if the pads are worn as shown in the figure.
Measure the wear of the friction linings
13. Inspect the disc for deformation, wear, broken rivets, weak springs and damaged grooves. Pull the disc onto the input shaft to ensure it is seated correctly and the grooves are not damaged or worn. Replace the disk with a new one if there is any doubt about its condition.
14. Check the release bearing for wear and deformation and make sure it rotates smoothly and moves easily toward the input shaft. It is recommended to replace the bearing every time the clutch is removed, unless the vehicle has traveled very little mileage since the last bearing replacement.
Make sure the bearing rotates smoothly and easily using a bearing puller |
The release bearing must move smoothly in the grooves |
15. Inspect the surface of the clutch housing, release lever and return spring for wear, cracks, deformation, etc. damage, replace if necessary.
16. Make sure that the clutch support bearing in the crankshaft rotates easily and smoothly (rotate it with your finger). Replace the bearing if necessary by removing it with a sliding hammer and installing a new one into the crankshaft recess using a socket or piece of tubing and a hammer. Lubricate the new bearing and install it as shown in the figure.
Check the rotation of the support bearing |
Remove the thrust bearing using a sliding hammer |
Install the support bearing assembly into the crankshaft recess
A = 2.45±0.3 mm
Installation
17. Before installation, apply a small amount of molybdenum grease to the release bearing and input shaft/friction disc grooves. Make sure that the lubricant does not come into contact with the rubbing surfaces of the friction disc, flywheel and pressure plate.
18. Install the friction disc onto the flywheel. Hold the friction disc with a special tool or a suitable round bar and install the pressure plate, aligning the alignment marks.
Friction disc in section - showing the correct orientation of the disc
19. Install the pressure plate bolts and tighten them in a diagonal pattern so that the pressure plate is flush with the friction disc. Center the disc relative to the clutch support bearing (at the end of the crankshaft), using a special alignment tool or a suitable round rod (photo).
The socket can be used as a clutch centering tool
Note: If the disc is not centered, the transmission will not install.
20. Tighten the pressure plate bolts by turning them half a turn in a diagonal sequence, using the tightening torque specified in the Specifications. Do not remove the alignment tool while tightening the bolts.
21. Install the release lever, fork, spring and bearing.
22. Remove the alignment tool and install the transmission.