Withdrawal
1. Drain the gearbox oil and brake fluid from the hydraulic clutch.
2. Remove a transmission.
3. Install drift 09411-25000 to center the clutch disc, which in this case will prevent the clutch driven disc from falling.
4. Gradually loosen the bolts securing the clutch assembly diagonally.
5. Loosen each bolt 1/2 turn 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 the height of the ends of the diaphragm spring. If there are defects, replace the clutch cover with the pressure plate.
2. Check the pressure plate for cracks, burn marks and surface wear.
3. Check the reliability of the rivet joints.
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. Measure the brake disc thickness.
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. Clear splines of a primary shaft of a transmission and establish on a shaft a disk of coupling. 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 while the engine is 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.
Lubricant: MOLYWHITE TA No. 2.
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. Install the clutch disc and center it with a special mandrel 09411-25000.
3. Install the clutch cover with the pressure plate on the flywheel guide pins. Gradually, in a diagonal sequence and in a certain order, tighten the flywheel mounting bolts. Tightening torque: 15–22 Nm.
4. Connect the bearing to the clutch release fork and install it on the casing sleeve.
Warning! Apply a light coat of MOLYWHITE TA No. 2 grease to the bearing bush groove and release fork contact points.
5. Install the release lever on the clutch release fork.
Warning! If the gearbox is mounted to the engine, do not perform this step as the clutch release bearing may be disengaged even though the clutch release fork turns freely.
6. Install the gearbox.
7. After performing the steps in step 6, push the release lever in the direction of the arrow and check that the clutch release bearing and housing are properly connected. The angle of rotation of the release lever must not exceed 3°. If the angle of rotation of the release lever is more than 3°, then the clutch release bearing and casing are connected incorrectly.