Removing
1. Remove manual transmission, refer to Section Removal and installation of the gearbox.
2. Loosen the Torx screws securing the clutch basket (arrows in the illustration) one after the other by 1 - 1½ turns so as to unload the disk. To prevent the flywheel from rotating when loosening the screws, hold it with a screwdriver or a retainer. Service stations use a special tool for this purpose (1).
Attention! If the Torx screws are not loosened evenly, the diaphragm springs may be damaged.
3. Then unscrew the fastening screws completely.
Attention! Remember or write down the position of the clutch disc in order to install it in its original position during assembly.
4. Take out a basket and a conducted disk of coupling.
Attention! Be careful not to drop discs when removing as otherwise, after installation, problems may occur in the operation of the clutch.
Examination
1. Check the pressure plate for hot spots 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 joints of the pressure plate and the basket for cracks, and the riveted joints for strength. Replace the basket with damaged or weak riveted joints.
4. Before installing a new clutch, remove the protective coating of the new clutch from the friction surfaces with a solvent. Then clean the friction surfaces of the driven and pressure disks 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 splines between the clutch disc and gearbox input shaft and lubricate with a light coat of MoS2 grease such as MOLYKOTE BR 2.
Attention! Do not apply too much lubricant, otherwise it may get on the friction surfaces of the clutch, resulting in malfunctions of the clutch. The amount of grease required is according to the size of the corn grain.
For dual mass flywheel engines, the splines are nickel plated, eliminating the need for lubrication. A hallmark of a dual-mass flywheel is the absence of damping springs.
2. Center the clutch disc using a suitable drift, eg HAZET 2174 or an old gearbox output shaft. If the clutch disc is not centered, it will not be possible to insert the gearbox output shaft later.
3. Install the clutch basket with the centered clutch disc onto the corresponding pins in the flywheel.
4. Screw in the basket fastening screws by hand, then tighten crosswise in several stages, each time by 1 - 1 ½ turns.
Attention! When tightening, make sure that the basket is evenly pressed against the flywheel. The tightening torque is specified in the Specifications.
5. Remove the centering drift.
6. Remove locking tool on flywheel if fitted.
7. Install the manual transmission, refer to Section Removal and installation of the gearbox.