Withdrawal
1. Access to clutch parts is usually sufficient after removing the box.
2. Remove the gearbox (see Chapter 7A). The engine must have additional temporary support at all times while the box is removed.
3. The clutch fork and release bearing remain in the gearbox.
4. To hold the basket while loosening the flywheel mounting bolts, insert a suitable tool into the disc hole.
5. Carefully inspect the clutch basket and flywheel. Find identification tags (usually the letters X or O painted in white). If no marks are found, apply your own mark.
6. Carefully unscrew the fastening bolts. Work in a criss-cross pattern until the pressure plate spring is completely released. Remove the basket and disc.
Inspection
7. Usually all clutch problems are related to the drive disc. However, attention is required to all components of the assembly.
8. Inspect the flywheel for cracks, burns, grooves and other defects. Light defects can be fixed by turning the flywheel to the recommended surface finish.
9. Examine overlays of a disk. They should protrude under the rivets by at least 1.5 mm. Check the presence of all rivets, warping, cracks in linings and hubs; the integrity of the springs and the absence of other defects.
Pic. 5.9 Clutch disc: 1 - overlay (wear); 2 - springs (cracks, deformation); 3 - sleeve (the splines must be free of wear, the sides are smooth); 4 - rivets (heads must be recessed).
10. When replacing the disc, we strongly advise you to replace the release bearing.
11. Examine a surface of a pressure plate and fingers of springs of a diaphragm. If the pressure plate is grooved or looks badly worn, replace it. Light spots can be removed with sandpaper.
Pic. 5.11 Pressure plate wear examples
Installation
12. Before installation, wipe the surfaces of the flywheel and pressure plate. Oil or grease must not come into contact with these surfaces. When assembling the clutch, the hands must be clean.
13. Reinstall the disc and clutch basket. Make sure the clutch disc is correctly oriented (there should be either marks or disc springs looking at the gearbox).
Pic. 5.13 Centering the clutch on the rail
14. Fit the bolts securing the basket to the flywheel and tighten them by hand.
15. Center the disc on the special tool. Tighten the bolts, working in a criss-cross pattern. The tightening pitch must be uniform to avoid skewing the basket. The final tightening torque is specified in the specification. Remove adjuster (see fig. 5.13).
16. Apply refractory grease to the inner groove of the release bearing (see Section 4), the contact surface of the fork and shaft.
17. Install release bearing (see Section 4).
18. Install the box and assemble the car.