Attention! When the clutch disc wears out, dust containing asbestos is formed, which is hazardous to your health. DO NOT blow or inhale dust with compressed air, DO NOT use gasoline or gasoline-based solvents to clean clutch components. Brake cleaner can be used to clean components. Wipe the clutch components with a clean cloth. then discard it in a closed container.
Removing
1. To access the clutch components, the transmission must be removed without removing the engine from the vehicle. Unless, of course, the engine is removed from the car (in case of serious damage), it makes sense at the same time to disassemble the clutch and inspect its condition. The relatively low cost and high labor intensity of access to clutch parts make it expedient to replace them every time an engine or gearbox is disassembled, without waiting for clutch components to wear out or break. If the engine cannot be removed, the following procedures must be followed.
2. Remove the gearbox from the car (see chapter 7A). When removing the gearbox, place props under the engine. It is preferable to support the engine from above. However, if you are going to put a jack under the engine, place a piece of wood between the jack and the engine (for load distribution).
Caution: The oil pump intake pipe is close to the bottom of the engine sump. If the sump flexes, you could damage the intake pipe, resulting in insufficient engine lubrication.
3. The release fork and bearing must remain on the gearbox housing.
4. Insert a disc centering tool to support the clutch disc when removing the pressure plate assembly.
5. Carefully inspect the flywheel and pressure plate housing and find the alignment marks on them. Typically, the labels are in the form of X or 0 characters, or as a letter drawn in white paint. If you can't find the marks, put them on the housing and on the flywheel to facilitate proper assembly of the clutch (pic. 6.5).
6. Gradually loosen the bolts securing the pressure plate casing to the flywheel (pic. 6.6). Loosen the bolts diagonally evenly until the spring is fully released. Then, while supporting the pressure plate, remove the bolts, remove the pressure plate assembly, diaphragm spring and clutch plate.
Examination
7. A common clutch failure is excessive wear on the clutch disc linings. However, when disassembling the clutch, it is necessary to carefully inspect all components.
8. Inspect the surface of the flywheel and make sure that there are no cracks, traces of overheating and scoring. If the defects are small, they can be eliminated by grinding the flywheel (we recommend performing this operation regardless of the condition of the flywheel surface). Crushing and installing the flywheel are described in chapter 2.
9. Examine overlays of a disk of coupling. From the working surface of the overlays to the rivets with which they are attached to the base, there must be at least 1.6 mm. Make sure there are no cracks in the linings and check the condition of the rivets, as well as the health of the springs (pic. 6.9). Usually, when disassembling the clutch, the clutch disc is replaced in any case. In addition, if you are not sure that the disk is in full working order, also replace it.
10. The release bearing is also replaced along with the clutch disc (see paragraph 7).
11. Inspect pressure plate surface and diaphragm spring (rice, 6.11, a, b). If the disc surface has annular wear or other damage, replace the pressure plate assembly. Check for obvious damage (cracks, chips, etc.). Minor defects on the surface of the disc can be corrected with sandpaper. If there is serious damage, purchase a new or remanufactured assembly.
12. Inspect the bearing mounted on the end of the crankshaft for wear or other damage. Replace bearing if necessary.
13. To remove the bearing, you will need a special tool or a suitable puller (pic. 6.13). This fixture (or puller) can be purchased from a hardware store.
Installation
14. Before installing a new crankshaft bearing, apply a little grease to its outer ring, then install the bearing in place (with a hammer or tool) (pic. 6.14).
15. Before assembling the clutch, thoroughly wipe the surface of the flywheel and pressure plate with brake cleaner or acetone. It is very important that there are no traces of oil on these surfaces. Install these parts only with clean hands.
16. Using a special tool, center the clutch disc in place with the pressure plate (pic. 6.16). Make sure all components are installed correctly. Most clutch discs are labeled "to flywheel" Or something like that. If there is no mark on the disc, install it so that the pads on the damper springs are facing towards the gearbox.
17. Wrap (only by hand) bolts securing the pressure plate housing to the flywheel. Tighten the bolts evenly.
18. Center the cordon disc. Make sure tool fits into clutch disc splines and crankshaft bearing. Move the tool from side to side to center the clutch disc. Tighten the pressure plate cover bolts evenly and diagonally to the end. Do not skew the pressure plate. After you wrap all the bolts, tighten them to the required torque. Remove the centering tool.
19. Lubricate the release bearing with high temperature grease (see paragraph 7). Also apply a small amount of grease to the working surfaces of the clutch fork, as well as to the neck of the cover of the input shaft of the gearbox (on which the release bearing moves).
20. Install release bearing (see paragraph 7).
21. Install the gearbox and all previously removed components.