Clutch
1 - clutch release fork; 2 - clutch release bearing; 3 - bolt, 15–22 Nm; 4 - clutch pressure plate; 5 - driven clutch disc.
Order of execution
1. Drain the gearbox oil and brake fluid from the hydraulic clutch.
2. Remove the gearbox.
3. Install drift 09411-11000 to center the clutch disc, which in this case will prevent the clutch disc from falling.
4. Gradually loosen the clutch assembly mounting bolts diagonally by turning each bolt by? turns until the action of the diaphragm spring stops and the bolts can be unscrewed by hand. Remove the clutch cover with pressure plate and clutch disc.
Warning! Do not clean the clutch disc or release bearing with solvent.
Warning! It is advisable to remove the flywheel and check the crankshaft rear O-ring for leaks. If necessary, replace the O-ring.
Checking the clutch cover with pressure plate
1. Check the diaphragm spring at the points of contact with the clutch release bearing for wear, cracks and determine the difference in height of the ends of the diaphragm spring. If there are defects, replace the clutch cover with the pressure plate.
- Diaphragm spring end height difference: 0.5 mm
2. Check the pressure plate for cracks, burn marks and surface wear.
3. Check the reliability of the rivet connections.
Checking the clutch disc
1. Check the reliability of the rivet connections of the friction linings to the clutch disc. If there are defects, replace the clutch disc.
2. Check the protrusion of the friction linings over the rivet heads. If the protrusion is less than acceptable, replace the clutch disc.
Protrusion: 1.1mm
3. Check the condition of the friction linings of the clutch disc and if there are traces of oil or mechanical damage on them, replace the clutch disc.
4. Clean the splines of the input shaft of the gearbox and install the clutch disc on the shaft. If the clutch disc is difficult to move along the shaft or the spline clearance is too large, replace the clutch disc and/or input shaft.
Checking the clutch release bearing
Warning! The clutch release bearing is sealed and must not be washed.
1. Check the condition of the clutch release bearing, which should rotate easily, evenly and silently, and there should be no play in it. The working surface of the bearing acting on the pressure spring must be smooth, without cracks, local corrosion or wear.
2. A defective clutch release bearing can be determined without removing it from the vehicle, for which it is necessary to press the clutch pedal with the engine running. If there is additional noise when you press the clutch pedal, then the clutch release bearing is defective and needs to be replaced.
Checking the clutch release fork
If there is uneven wear at the contact points of the clutch release fork with the bearing, replace the clutch release fork.
Installation
1. Apply grease to the contact surfaces of the bearing, cylinder and clutch release fork.
Warning! When installing the clutch, apply grease to all moving parts, but do not use excessive grease, as this may cause the clutch to slip.
2. Apply grease to the groove of the clutch release bearing.
Lubricant: CASMOLY L9508
3. Apply grease to the contact surfaces of the clutch release fork support.
Lubricant: CASMOLY L9508
4. Use fine sandpaper to clean the flywheel and pressure plate surfaces and ensure that all abrasive material and grease is removed from the cleaned surfaces.
5. Apply grease to the clutch disc splines and gearbox input shaft.
Lubricant: CASMOLY L9508
6. Install the clutch disc and center it with special tool 09411-11000. When installing the clutch disc, the marked surface of the disc must be on the side of the pressure plate.
7. Install the clutch cover with pressure plate on the flywheel guide pins.
8. Gradually, in a diagonal sequence and in a certain order, tighten the flywheel mounting bolts.
Tightening torque: 15–22Nm
9. Remove the mandrel centering the clutch disc.
10. Install the gearbox.
11. Adjust the clutch pedal free play.