Warning: Dust from worn clutch components may contain asbestos, which is harmful to health. DO NOT blow dust off components with compressed air and avoid breathing in any particles that may become airborne. DO NOT use gasoline or mineral spirits to remove dust - use a special cleaner or methylated spirits only. Wipe clutch components with a clean rag
Note: Although some companies make asbestos-free friction linings, it is safer to assume that the linings installed on your vehicle are not of this "safe" type and take the precautions described above.
Removal
1. The clutch can be accessed when the power unit is removed from the vehicle for major repairs (see Section 2), or by removing the transmission as described in Section 7.
2. Before removing the clutch, apply alignment marks to the pressure plate assembly and flywheel using a suitable marker or quick-drying paint (see photo).
3. Loosen the pressure plate mounting bolts in a diagonal sequence, turning them half a turn at a time. Do this until the spring pressure is relieved, after which the bolts can be unscrewed by hand. Remove the bolts together with the washers.
4. Remove the pressure plate assembly from the flywheel and remove the friction disc, noting its correct orientation (see photo).
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Inspection
Note: Due to the time and labor involved in accessing the clutch components, it is recommended that the friction disc, pressure plate assembly, and release bearing be replaced even if only one of these components is actually worn.
5. Remove the clutch assembly.
6. See the Warning given at the beginning of this Chapters, and clean the clutch components.
(Information published on the website SkodaBook.ru)
7. Check the friction disc linings for damage, signs of wear and oil stains. If the lining is cracked, burnt, has worn areas or other types of damage, or if it is contaminated with oil or grease (shiny black spots), the friction disc must be replaced.
8. If the friction linings are still serviceable, check that the hub grooves are not worn, that its damper springs are intact and securely fastened, and that all disc rivets are in place and holding tightly. If any damage or signs of wear are found, replace the friction disc.
9. If the friction lining is contaminated with oil, this may be caused by a leak through the left crankshaft oil seal (shaft end facing the flywheel), oil pan/cylinder block joint or transmission input shaft seal. Replace seal or gasket (see Section 2 or 7) before installing a new friction disc.
10. Inspect the pressure plate assembly for damage and signs of wear. Shake the plate to check for loose rivets and wear/damage to the diaphragm spring support rings. Make sure the plates that secure the pressure plate to the clutch cover do not show signs of overheating (bright yellow or blue spots). If the diaphragm spring is worn or damaged, or if its pressure has weakened, the pressure plate assembly must be replaced.
11. Inspect the machined running surfaces of the pressure plate and flywheel: they should be clean, smooth and free of scratches or burrs. If the surface has become discoloured from overheating or cracked, the component should be replaced, although minor damage of this nature can sometimes be ground off using sandpaper. Alternatively, have the flywheel reground by a specialist (see Chapter 12 Section 2).
12. Check the condition of the release bearing as described in Chapter 5 of this Section.
Installation
13. When reassembling, ensure that the flywheel and pressure plate running surfaces are absolutely clean, smooth and free of oil and grease. Use solvent to remove protective grease from new components.
14. Install the friction disc so that the longer part of its hub faces the flywheel. Install the pressure plate assembly, aligning the marks made during removal if installing the old disc. When installing a new pressure plate assembly, it can be located in any direction.
15. Install the pressure plate mounting bolts and washers and tighten them only by hand for now, so that the friction plate can still move.
16. Now the friction disc must be centered so that when installing the transmission, its input shaft freely enters the grooves of the disc hub.
17. Insert a screwdriver or other long rod into the friction disc hub so that the tool rests against the recess in the crankshaft; then move the disc to the desired side until it is exactly in the center. Alternatively, you can use a special centering tool - it is sold in many auto parts stores. You can also make such a tool yourself. To do this, you will need a metal rod or a wooden dowel, the diameter of which is slightly smaller than the diameter of the recess in the end of the crankshaft. You need to wind insulating tape on the rod so that you get a thickening corresponding to the diameter of the splined hole of the friction disc.
18. After the friction disc is centered, tighten the pressure plate bolts evenly in a diagonal sequence to the specified tightening torque Specifications (see photo).
19. Apply a small amount of molybdenum grease to the grooves of the friction disc and transmission input shaft, as well as to the release bearing hole.
20. Install the transmission as described in Section 7.