Removal and installation of clutch
Note: Clutch pressure and driven plates are replaced only as a pair.
1. Remove manual transmission (see Section 5).
2. For several approaches, turn out the bolts securing the pressure plate in a diagonal order and remove the clutch basket assembly. Use MP1-223 or N°3067 to prevent flywheel from turning (see illustration 8.10).
3. On models with clutch "Sachs" after unscrewing the bolts, the stopper (2 to resist. illustrations) with a finger (1) should weaken. If it doesn't, push your finger towards the flywheel.
8.3 Finger (1) and stopper (2)
4. Remove the clutch basket.
5. The driven disk is installed with the inscription "Getriebeseite" or "side of gearbox" and a protruding cage of springs to the side of the manual transmission.
6. Check up a condition of petals of a diaphragm spring. Wear of their edges up to half the thickness is allowed. Make sure there are no cracks in the diaphragm spring petals between the pressure plate and cover. Make sure the rivets are not loose. If a new pressure plate is installed "LuK", check the position of its adjustment mechanism as described in the subsection below.
7. Drive plate linings must be free of grooves or traces of oil/grease. The corresponding surface of the flywheel must also be free of oil or grease.
8. Clean the manual transmission input shaft splines and driven disc hubs if using an old driven disc. Remove corrosion and apply a very thin coat of G 000 100 grease to the input shaft splines. Then move the clutch disc back and forth on the input shaft until the hub is free to move on the shaft. Remove excess lubricant.
9. The pressure plates are supplied with corrosion protection and lubrication, so only their contact surface should be cleaned to prevent deterioration of their service life.
10. Install the pressure plate on the centering pins and center it using a suitable mandrel (see resist. illustration):
- on models with manual transmission "02Q" - T10097;
- on models with manual transmission "0AJ" - T10086;
- on models with manual transmission "0A4" - MPZ-475A.
8.10 Centering the clutch (bushing Т10372 is used)
11. On a Sachs clutch, make sure the lock pin is (position sensor) can be moved freely (see resist. illustration).
8.11 Locking pin
12. Install the pressure plate on the dowel pins. Make sure that the contact surface of the pressure plate and the lining of the driven plate are in full contact with the flywheel - only then insert the clutch mounting bolts and tighten them by hand until they touch the pressure plate. After that, on the Sachs clutch, the locking pin (see illustration 8.11) should rise from the pressure plate. Evenly, in several passes, tighten the clutch mounting bolts in a diagonal pattern to the required torque. At the same time, do not disturb the centering of the clutch. Use tool #3067 or MP1-223 to prevent flywheel from turning.
Checking the position of the pressure plate adjusting mechanism "LuK"
13. Both edges (And on the opposite illustrations) adjusting ring must be located between the two risks (IN).
8.13 Checking the position of the adjusting mechanism
14. If the adjusting ring occupies a different position in the new pressure plate, it is not allowed to install the pressure and driven discs.
15. On a used clutch, the adjusting ring may be outside the marks.