1. Adjusting washer for «K1»
2. Large release fork «K1»
3. Hinge
4. Small clutch release bearing «K2»
5. Adjusting washer for «K2»
6. Guide bush, top
7. Small clutch release fork «K2»
8. Ball joint
9. Fastening screw, tightening torque 8 Nm + tighten by 90°degrees
10. Guide bush, lower part.
First of all, you need to determine the size «IN», shown in the figure below.
1. Using special pliers, remove the ball joint as shown in the figure below.
2. Install a new ball joint as shown in the figure below.
Note. Press down on the ball joint to install it by hand, if necessary, carefully apply a few blows with a rubber mallet.
3. Install the old retaining ring on the gearbox shaft as shown in the figure below.
4. Install a special ruler on the clutch crater (Т40100), as shown in the figure below.
Note. Ensure that the ruler is installed in one position, exclude its movement when performing any operations.
5. Install a depth gauge with a dial indicator on the ruler (A). Install the depth gauge plate on the shaft (IN), as shown in the figure below.
6. Set the dial indicator to zero.
7. Measure the distance to the retaining ring.
8. Mark the result as "IN 1", eg: size "IN 1" = 2.62 mm.
9. Repeat distance measurement «IN» from the opposite side.
10. Record the result as «AT 2», eg: size «AT 2» = 2.58 mm.
Note. Do not measure at the snap ring lock. The ring may loosen over time, and this will affect the accuracy of the measurements.
11. Calculate the arithmetic mean of the two values obtained above.
«IN» = (81 + B2) /2 = 2.60 mm
12. Remove the retaining ring from the gearbox shaft as shown in the figure below.
Note. This ring must be replaced with a new one during installation.
Determine distance «A1» for selecting the shim of the larger release fork «K1».
1. Install the large clutch release fork into the clutch housing as shown in the figure below.
2. Install special tool (Т10466) onto the larger release bearing as shown in the figure below.
3. Apply pressure by hand and at the same time rotate this special tool. Check the rotation of the release bearing. Install the special tool properly.
4. Install a depth gauge with a dial indicator on top of the gearbox input shaft as shown in the figure below. Set the dial indicator to zero.
5. Measure the distance from the gearbox shaft to the special tool (Т10466), as shown in the figure below.
6. Repeat the above measurement on the opposite side of the special tool as shown in the figure below. This is necessary to avoid influence on the measurement results due to bearing runout.
7. Calculate the arithmetic mean of the two values obtained from the measurements described above.
8. Write the resulting number as «A1».
difference between «A1» and «IN», is the value of the depth of the clutch release bearing «K1».
9. Continue calculation. To do this, you need to pay attention not to the housing of the new clutch and read the inscription shown in the figure below. The example below shows the inscription «K1» +0.0. For the final calculation, which will allow you to select the adjusting washer, it is necessary to the obtained value «K1» add the value that is written. Example: if «K1» = 2.32 mm, then the thickness of the shim: 2.32 + 0.0 = 2.32.
10. Select an adjusting washer from the standard range with a thickness closest to the theoretically calculated value. The standard range of shims is shown in the table below.
Attention. It is necessary to install only one adjusting washer, no more.
Note. The shim is installed during the final assembly of the clutch.