Removal
1. The clutch cannot be replaced without removing the engine and gearbox. Remove each unit in the appropriate manner. Follow the instructions below.
2. Mark the installation position of the clutch in relation to the flywheel. Use a punch to do this.
3. Loosen the six clutch bolts in a diagonal sequence to relieve the diaphragm spring pressure. To do this, properly lock the flywheel.
4. Remove the clutch and take out the friction disc. If the clutch is hanging on the flywheel mounting pins, carefully press it out with a screwdriver. Note that the more protruding side of the friction disc hub is directed towards the gearbox, i.e. outward.
5. Immediately wipe the inside of the flywheel with a rag and inspect its friction surface. If the friction disc is worn down to the rivet heads, the flywheel surface may be damaged. If the engine is separated from the gearbox, the clutch must always be disconnected.
Bulkhead
6. Check the pressure plate and cover for damage or wear. If any, replace both components as a set.
7. Inspect the friction disc spring and hub for wear. Since oily friction linings cannot be cleaned, the friction disc will have to be replaced.
8. The damper springs of the friction discs are of different colors. Measure the thickness of the friction linings. If it is less than 0.30 mm or is about to reach the wear limit, replace the disc.
9. To measure the runout of the friction disc, place it on a suitable punch mounted on a lathe
10. Place the micrometer with dial on a special holder so that the measuring finger touches the edge of the disk (see illustration).
3.10 Measure the friction disc runout
11. Slowly rotate the disc and observe the micrometer reading. If the reading is greater than 0.4 mm, the disc can be adjusted if desired by gently tapping it with a mallet. Otherwise, replace the disc.
12. Make sure that the friction disc hub moves freely in the grooves of the gearbox input shaft.
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13. If the runout is more than 0.4 mm, the shaft gear engagements are worn. The cause of this is usually the friction disc.
14. Inspect the inner surfaces of the pressure spring sectors for wear. If deep wear marks are observed, replace the clutch completely.
15. The petals of the pressure spring must be in the same plane within 0.5 mm at the top. Deformed petals must be aligned using a special tool.
16. Place a measuring ruler on the friction surface of the pressure plate (see illustration) and measure the gap with a feeler gauge. If the gap exceeds 0.3 mm, replace the clutch.
3.16 Check the inner surface of the pressure plate for wear
Installation
17. Perform installation in reverse order, paying attention to the following:
- a) If the same clutch is installed, take into account the marks made during removal. The new clutch can be oriented in any way.
- b) The friction disc is centered by eye.
- c) Tighten the mounting bolts evenly in a diagonal sequence to a tightening torque of 25 Nm. The flywheel must be locked.
- d) Connect the gearbox to the engine and install the power unit on the vehicle.