Warning! When the clutch is in operation, dust is generated that contains asbestos, which is harmful to health, so when cleaning the clutch, do not use compressed air or inhale the dust. Clean the clutch parts from dust using brake fluid or methyl alcohol. After cleaning the clutch parts using methyl alcohol or brake fluid, wipe the parts dry.
Clutch
1 – clutch disc; 2 – leading clutch assembly with pressure plate; 3 – release bearing; 4 – clutch release fork; 5 – clutch housing; 6 – clutch slave cylinder; 7 – hydraulic tubes; 8 – clutch master cylinder; 9 – clutch pedal
Removal
Removal the leading part of the clutch from the flywheel
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1. Remove the gearbox.
2. Mark the position of the clutch master assembly in relation to the flywheel using a marker or paint.
3. Gradually loosen the clutch master assembly mounting bolts in a diagonal sequence, turning each bolt half a turn until the spring force is released and the bolts can be removed by hand.
4. Remove the clutch master assembly and clutch disc from the flywheel (see Fig. Removing the leading part of the clutch from the flywheel). When removing, use caution as the clutch disc may fall out of the clutch drive. Note the orientation of the clutch disc in relation to the flywheel. The larger protrusion of the clutch disc hub should be towards the gearbox.
Examination
1. Check the clutch disc linings for wear, mechanical damage or oil contamination.
2. If these defects are present, the clutch disc must be replaced.
3. If the friction linings are in good condition and not worn down to the grooves, the damper springs are securely fastened and the riveted connections are not loose, then the clutch disc can be installed in the car.
4. If the clutch disc is contaminated with oil, check the left crankshaft or transmission input shaft oil seal. Replace the seals if necessary before installing a new clutch disc.
5. Check the drive disc assembly for wear on the pressure plate, mechanical damage, reliability of the riveted joint, damage to the clutch diaphragm spring. If the diaphragm spring is worn or damaged, or there is a suspicion that the elasticity of the spring has changed, then it is necessary to replace the drive disc assembly.
6. Check the working surfaces of the pressure plate and flywheel that mate with the clutch disc linings. They should be clean, flat and free of scratches and wear.
7. Check the thrust bearing, which should rotate easily, evenly and quietly. The working surface of the bearing, which acts on the thrust spring, should be smooth, without cracks, local corrosion or wear.
Installation
Installing the clutch disc on the flywheel
When installing the clutch disc on the flywheel, the inscription on the disc "engine side" or the smaller side of the hub should be facing the flywheel.
Using a mandrel to center the clutch disc
1. When installing new clutch discs or pressure plate, remove the anti-corrosion protection from them.
2. When installing the clutch disc, make sure that no oil gets on its friction lining, even in small quantities. Therefore, before installing the clutch disc, wipe the mating surface of the flywheel and the surface of the pressure plate with a clean rag, and install the clutch disc with clean hands.
3. Lubricate the splines in the clutch disc hub with a thin layer of special grease based on molybdenum disulfide. Install the clutch disc on the flywheel so that the inscription on the clutch disc "engine side" or the smaller side of the hub was facing the flywheel (see Fig. Installing the clutch disc on the flywheel). When installing the clutch drive part, press the clutch disc against the flywheel.
4. Install the clutch master part by aligning the marks on the flywheel and the clutch master part. Check that the mounting holes on the clutch master part are aligned with the mounting pins on the flywheel. Tighten the clutch master part mounting bolts so that the clutch disc is pressed down, but at the same time can still move sideways.
5. Using a drift or an old transmission input shaft, center the clutch disc relative to the flywheel (see Fig. Using a mandrel to center the clutch disc).
6. After centering the clutch disc, tighten the clutch master cylinder mounting bolts gradually and in a diagonal sequence to the specified torque. Remove the mandrel from the clutch disc.
7. Lubricate the splined portion of the gearbox input shaft and the release bearing guide sleeve with a thin layer of special molybdenum disulfide-based grease.
Attention! The lubricant layer must be thin and uniform, otherwise, when the clutch is operating, excess lubricant will be thrown onto the working surfaces of the clutch, which may disrupt its operation.
8. Install the gearbox.