Removal
1. Remove the manual transmission, refer to Section Removal and installation of gearbox.
2. Loosen the Torx screws securing the clutch basket (arrows in the illustration) one after another by 1 – 1Ѕ turns so as to relieve the disk. To prevent the flywheel from rotating when unscrewing the screws, hold it with a screwdriver or a clamp. Service stations use a special tool (1) for this purpose.
Caution: If the Torx screws are not loosened evenly, this may result in damage to the diaphragm springs.
3. Then unscrew the mounting screws completely.
Attention! Remember or write down the position of the driven clutch disc so that you can install it in its original position during assembly.
4. Remove the clutch basket and driven disc.
Caution! Do not allow the discs to fall when removing, otherwise problems with the clutch operation may occur after installation.
Examination
1. Check the pressure plate for overheating and grooves, replace if necessary.
2. Check the wear of the diaphragm spring tongues and their height; if necessary, carefully bend the ends of the springs.
Attention! Spring wear should not exceed 0.3 mm.
3. Check the connections of the pressure plate and basket for cracks, and the rivet connections for strength. Replace the basket with damaged or weak rivet connections.
4. Before installing the new clutch, remove the protective coating of the new clutch from the friction surfaces with solvent. Then clean the friction surfaces of the driven and pressure plates with coarse sandpaper.
5. Oily or mechanically damaged disc - replace.
6. Check the clutch release bearing in the gearbox housing for noise, leaks and wear, replace if necessary.
Installation
1. Clean the splined joints of the clutch disc and the gearbox input shaft and lubricate with a thin layer of MoS2 grease, for example, MOLYKOTE BR 2.
Caution! Do not apply too much grease, otherwise it may get on the friction surfaces of the clutch, which will lead to clutch malfunctions. The required amount of grease corresponds to the size of the corn grain.
In engines with a dual-mass flywheel, the splined connection is nickel-plated, which eliminates the need for lubrication. A dual-mass flywheel is characterized by the absence of damping springs.
2. Center the clutch disc using a suitable drift, such as HAZET 2174 or the old secondary shaft of the gearbox. If the clutch disc is not centered, it will not be possible to insert the secondary shaft of the gearbox later.
3. Install the clutch basket with the centered clutch disc onto the corresponding pins in the flywheel.
4. Screw in the basket mounting screws by hand, then tighten them crosswise in several steps, each time by 1 - 1 ½ turn.
Caution! When tightening, make sure that the basket is pressed evenly against the flywheel. The tightening torque is specified in the Specifications.
5. Remove the centering punch.
6. Remove the flywheel locking tool if installed.
7. Install the manual transmission, refer to Section Removal and installation of gearbox.