Warning: Clutch wear dust that settles on clutch components contains asbestos, which is hazardous to health. Do not blow off this dust with compressed air or inhale it. Do not remove dust with gasoline or gasoline-based solvents. Asbestos dust should be washed off with brake cleaner into a tray. After wiping the clutch components dry with a rag, place the rag and used cleaner in a labeled, closed container.
Removal
1. The clutch components are accessible after the transmission has been removed, leaving the engine in place. However, if the engine has been removed for rebuilding, the clutch wear should also be checked and worn components replaced if necessary. Since clutch components are inexpensive compared to the time and effort required to access them, they should be replaced each time the engine or transmission is removed unless they are in perfect condition. The procedure below assumes that the engine is in place.
2. Remove the transmission from the vehicle as described in Chapter 7 Part A. While the transmission is removed, you need to place a support under the engine. It is preferable to support the engine with a winch from above. When using a jack, place a wooden block under the engine tray to distribute the load.
Caution: The oil pump intake is located very close to the bottom of the oil pan. If the oil pan is warped, the intake may become clogged.
3. The release fork and release bearing can be left attached to the transmission for a while.
4. To support the clutch disc during removal, insert the clutch installer through the clutch disc bushing.
5. Carefully inspect the flywheel and clutch housing for index marks. The marks are usually an X or O or a white letter. If you cannot find the marks, apply your own marks to the pressure plate and flywheel to ensure proper assembly.
6. Slowly loosen the clutch housing to flywheel bolts, loosening each bolt only a quarter turn at a time. Loosen the bolts in a diagonal pattern until the spring tension is completely released. Then, holding the clutch housing, pull the bolts out completely and remove the housing and clutch driven disc.
Examination
7. Clutch failure is usually associated with wear of the driven clutch disc. However, all components should be checked.
8. Inspect the flywheel for cracks and other signs of damage. If there is minor damage, the surface can be machined. This is also recommended regardless of the appearance of the surface. The procedures for removing and installing the flywheel are described in part A Chapter 2.
9. Inspect the clutch slave disc linings. The lining height above the rivet heads should be at least 1.2 mm. Make sure there are no loose rivets, warps, cracks, broken springs or other obvious damage. As stated above, the clutch disc is usually always replaced, so replace it regardless of the disc condition.
3.9. Clutch slave disc. 1. Overlay - wears out with use, 2. "Flywheel Side" or similar mark, 3. Rivets - secure the overlay and can damage the pressure plate if they come into contact with it
10. The release bearing should be replaced together with the clutch disc (see section 4).
11. Check the condition of the machined surfaces and petals of the clutch housing diaphragm spring. If there are deep scratches or other surface damage, replace the clutch housing assembly. Also pay attention to obvious damage, bending, cracks, etc. The formation of a slight gloss can be removed with medium-grain sandpaper. A new disc or a factory-reconditioned disc can be used to replace the clutch housing.
Installation
12. Before installation, wipe the treated surfaces of the flywheel and clutch housing clean with solvent or acetone. It is important that there is no grease on these surfaces or on the friction linings of the clutch disc. Handle these parts only with clean hands.
13. Align the clutch disc and housing using the installation tool. Make sure it is installed correctly (most clutch discs are marked "flywheel side" or similar - if not, install the clutch disc with the damper springs or shock absorbers facing the transmission).
3.13. Center the clutch disc on the pressure plate using a special tool
14. Tighten the pressure plate to flywheel mounting bolts around the circumference of the pressure plate using finger force only.
15. Center the clutch disc by inserting the installation tool through the toothed sleeve into the crankshaft pilot bearing. Rock the tool until it stops in the pilot bearing. Tighten the clutch cover to flywheel bolts evenly in a diagonal sequence to avoid warping the cover. After all bolts have been pre-tightened, tighten them to the torque specified in the specifications in this Chapter. Remove the installation tool.
16. Lubricate the inner groove of the release bearing with high-temperature grease (see section 4). Also apply grease to the contact surfaces of the clutch release fork and the release bearing guide.
17. Install the clutch release bearing into place as described in section 4.
18. Install the transmission, clutch slave cylinder and all previously removed components, tighten all fastening elements to the required torque.