Pic. 3.18. Cover and clutch disc
Withdrawal
Drain the clutch fluid and oil from the gearbox housing.
Remove the gearbox.
Pic. 3.19. Installing the mandrel in the hole of the hub of the driven disk
Insert Drift 09411-25000 into the driven disc hub hole to prevent it from falling (pic. 3.19).
Loosen the bolts securing the clutch cover to the flywheel in a criss-cross pattern.
Pic. 3.20. Unscrewing the bolts securing the clutch cover to the flywheel
Loosen the bolts alternately one or two turns each time to prevent warping of the casing flange (pic. 3.20).
Attention! Do not use solvents to clean the driven disc and clutch release bearing.
Checking the clutch cover
Check the ends of the diaphragm spring petals for wear and height differences.
Check pressure plate surface for wear, cracks and discoloration.
Check for loose rivets and replace clutch cover if necessary.
Drive Drive Check
Pic. 3.21. Checking the protrusion of the friction linings
Check friction linings for loose rivets, uneven fit, sticking damage, oil or grease build-up. If necessary, replace the damaged driven disk (pic. 3.21).
Pic. 3.22. Checking the thickness of the driven disk in a free state
Check the thickness of the driven disk in a free state (pic. 3.22).
Check disc springs for play and damage and replace defective disc if necessary.
Clear splines of a primary shaft of a transmission and establish a conducted disk.
If it is difficult to move the disc along the splines of the shaft or if there is excessive clearance, replace the driven disc and / or the input shaft of the gearbox.
Clutch bearing check
Check the clutch release bearing for binding, damage or excessive noise. Also check the contact points of the diaphragm spring for wear.
Replace the bearing in case of severe wear of the contact points with the clutch release fork.
Attention! Since the clutch release bearing is lubricated, do not use solvents to clean the bearing.
Checking the clutch fork
Replace the clutch release fork if it is heavily worn where it contacts the clutch release bearing.
Installation
Pic. 3.23. Application points for universal grease
Apply multipurpose grease to the release fork where it contacts the release bearing and slave cylinder (pic. 3.23).
Attention! When installing the clutch, do not apply grease in the places indicated in Figure 3.24 in excessive quantities, because this can cause slippage and clutch jerking.
Pic. 3.24. Points for applying universal grease to the bearing groove
Apply CASMOLY L9508 multipurpose grease to the clutch release bearing groove (pic. 3.24).
Apply CASMOLY L9508 multipurpose grease to the release fork where it contacts the release lever shaft.
Thoroughly clean the surfaces of the flywheel and pressure plate with sandpaper or fine sandpaper and check that there are no traces of oil or grease on them.
Apply a small amount of CASMOLY L9508 Multipurpose Grease to the splines of the driven disc hub and transmission input shaft.
Attention! Apply only the required amount of lubricant. Excess lubrication can cause clutch slip and jerks.
Pic. 3.25. Installation of a conducted disk on a flywheel
Using drift 09411-25000, install the driven plate on the flywheel with the factory marked side to the pressure plate (pic. 3.25).
Install the clutch cover on the flywheel and tighten the six mounting bolts.
Tighten the bolts crosswise to 15–22 Nm. Tighten the bolts alternately one or two turns each time to prevent warping of the clutch housing flange.
Remove the mandrel to center the driven disk.
Install the gearbox.
Adjust the clutch pedal free play.