Withdrawal
Remove gearbox.
To prevent the flywheel from turning when the bolts are loosened, lock it at the ring gear with tool -1- or with a wrench and a pin. Loosen the clutch pressure plate mounting bolts sequentially by 1 or 1.5 turns until the tension of the pressure plate is relieved.
Attention: If the bolts are released completely immediately, the diaphragm spring and the guide pins between the pressure plate and the flywheel are damaged due to misalignment.
After that, unscrew the bolts completely.
Remove the clutch pressure and driven discs.
Attention: Do not drop the discs when removing, otherwise, after assembly, difficulties may arise associated with pulling the clutch and separating the discs.
Wipe flywheel.
Examination
Check the clutch pressure plate for roughness and burn cracks.
Examine the diaphragm spring for damage -arrows-.
Check spring connections between pressure plate and cover for cracks. strength of rivet joints and reliability of installation. Replace clutch with damaged or loose rivets.
Check the contact surface of the pressure plate for cracks, burns and wear. Pressure plates with an inward deflection of up to 0.3 mm can be installed again. Checking is carried out with a metal ruler and a probe.
Check the engine flywheel for cracks from burns and unevenness and replace if necessary. After each release, install new bolts with micro-shell. If the old flywheel remains on the engine, replace the mounting bolts only if oil comes out. Tighten the flywheel bolts crosswise to 105 Nm.
Sand the pressure plate and flywheel with very fine sandpaper.
Replace the clutch disc with traces of oil and grease, as well as with mechanical damage.
Check the driven disk for sufficient lining thickness with a vernier caliper. The minimum allowable lining thickness is 7.5 mm, otherwise replace the driven disc. The same should be done if there are cracks on the linings.
In the workshop, the driven discs can be checked for runout. The maximum allowable lateral runout can be 0.5 mm.
Attention: This check is necessary when the old driven disc has to be reinstalled and the clutch has previously disengaged incorrectly.
Clutch Release Bearing remove from gearbox bearing tube and check.
Check the deep groove ball bearing in the crankshaft for ease of movement. If necessary, remove the bearing using an internal puller and replace with a new one.
Installation
Attention: Before installing a new clutch, remove anti-corrosion grease from the friction surfaces of the pressure plate without residue and, if necessary, wipe the working surface of the flywheel clean with a solvent.
Insert driven plate -2- and pressure plate -3- into flywheel -1-.
Attention: The flat side of the driven plate must face the flywheel, see illustration. The slave disk has the inscription Getniebeseite (gear side). After installing the disk, this inscription should be readable. Place the pressure plate on the appropriate guide pins.
The driven disk must be centered with a suitable pin -1- during installation (e.g. HAZET 2174), or using an old gearbox input shaft. 2 - a device for locking the flywheel.
Tighten the pressure plate mounting bolts sequentially by 1-1.5 turns until the pressure plate is firmly tightened. Make sure that the pressure plate, when tightening the bolts, enters the flywheel evenly and without touching the edges. The tightening torque depends on the accuracy class of the fastening bolts, which is stamped on their heads. Bolts of accuracy class 8.8 are tightened with a torque of 25 Nm, and bolts of accuracy class 10.9 are tightened with a torque of 35 Nm.
Remove center pin.
If installed, remove flywheel locking tool.
Lubricate the splines of the gearbox input shaft very thinly with ESSO UNIREX S2 grease.
Caution: Do not apply too much lubricant. The required amount of lubricant should not exceed the size of a grain of rice in volume. After applying lubricant, move the clutch disc back and forth along the gearbox input shaft until the hub can easily walk along the shaft. Excess grease must be removed, otherwise malfunctions may occur during operation of the clutch.
Install gearbox.