Clutch cable replacement

Clutch Cable Replacement Clutch cable replacement

In the cabin, under the instrument panel, with a key of 8, unscrew the nut that secures the cable sheath bracket to the pedal assembly bracket.

Use a slotted screwdriver to pry off the spring clip and remove it from the groove of the clutch pedal finger.

Clutch cable replacement Clutch cable replacement

Remove the eye of the housing of the automatic cable length adjustment mechanism from the clutch pedal pin.

We remove the upper part of the cable from the bracket of the pedal assembly.

Clutch cable replacement Clutch cable replacement

In the engine compartment, pulling the cable forward, remove the cable leader from the groove of the clutch fork lever

Rotating counterclockwise, we unscrew the leash from the threaded end of the cable.

Clutch Cable Replacement Clutch cable replacement

Remove the rubber protective cover from the tip of the cable

Remove the tip of the cable sheath from the bracket hole on the gearbox

In the cabin, take out the sealing cover of the cable from the hole in the bulkhead and pull the cable into the cabin

Clutch cable replacement Clutch cable replacement

Before installing the cable, check the condition of the plastic sleeve on the pedal finger (Fig. 10).

We replace the worn bushing with a new one and apply grease to the pin.

Install the cable in the following sequence:

  • - we pass the cable through the hole in the front panel from the passenger compartment to the engine compartment;
  • - install the sealing cover in the hole of the bulkhead;
  • - we put the automatic cable length adjustment mechanism on the pedal finger and fasten it;
  • - we screw a plastic leash onto the threaded end of the cable so that the end of the cable end is flush with the end of the leash;
  • - put the leash into the groove of the clutch fork lever;
  • - adjust the clutch drive.

To do this, pull the cable by the threaded tip forward to the stop, overcoming the force of the clutch pedal spring, and hold the cable in this position.

clutch cable replacement

With a caliper we measure the distance from the end of the plastic leash to the clutch release fork lever, which should be 27 mm (Fig. 11).

If necessary, rotate the leash to achieve the required distance.

When the load is released (the cable is released), the leash must rest against the fork arm without any play.

After that, press the clutch pedal three times to activate the automatic cable length adjustment mechanism.

Total pedal travel must not exceed 146 mm.

Replacing the casing and clutch disc

We perform work on a viewing ditch or overpass.

Remove the gearbox.

Clutch cover and disc replacementClutch cover and disc replacement

We screw the M12x1.25 stud into the threaded hole of the cylinder block (or the bolt securing the clutch housing to the cylinder block).

We insert a mandrel or primary roller from the VAZ classic gearbox into the holes of the crankshaft and the driven disk.

We insert the mandrel so that the basket and the driven disk do not fall during unscrewing.

Clutch cover and disc replacement

Having installed the mounting blade between the teeth of the flywheel and resting it on the screwed-in stud or bolt, turn off the six bolts securing the clutch cover to the flywheel with a head of 8.

We unscrew the bolts evenly, each no more than one turn per pass, so as not to deform the clutch cover.

If it is difficult to unscrew the bolts, we tap their heads with a hammer with a soft metal tip.

Clutch cover and disc replacementClutch cover and disc replacement

Remove the clutch basket

Remove the clutch disc

Install the clutch basket and driven disc in reverse order

When installing, orient the clutch disc with the protruding part of the hub towards the basket.

We insert the centering mandrel into the slots of the driven disk and insert the mandrel shank into the hole of the crankshaft flange.

Tighten the bolts securing the basket evenly diagonally.

Final tightening torque 19-30 Nm.

After installing the gearbox, we adjust the clutch cable.

Removing the clutch release mechanism

Remove the gearbox

Removing the clutch release mechanismRemoving the clutch release mechanism

We take the ends of the spring clip away from the tabs of the clutch release bearing housing.

Remove the clutch release bearing assembly with the casing from the guide sleeve.

Removing the clutch release mechanismRemoving the clutch release mechanism

Remove the clutch release bearing spring clip.

To remove the clutch release fork, use sliding pliers to compress the petals of the plastic sleeve and pry the sleeve with a slotted screwdriver.

Removing the clutch release mechanism

Remove the sleeve from the hole in the clutch housing.

During subsequent assembly, the protrusion on the shoulder of the sleeve must fall into the groove (shown by the arrow) of the crankcase.

Removing the clutch release mechanismRemoving the clutch release mechanism

From the inside of the clutch housing, we squeeze out the dirt-proof rubber cover of the clutch release fork lever.

Remove the cover from the lever.

Removing the clutch release mechanismRemoving the clutch release mechanism

Raise the fork so that its lower part comes out of the hole of the metal sleeve pressed into the clutch housing boss, and remove the clutch release fork, pulling the fork lever through the window in the crankcase.

Using a 10 head with an extension, unscrew the three bolts securing the guide sleeve to the clutch housing

Removing the clutch release mechanism

Remove the bushing

We install the parts of the clutch release mechanism in the reverse order.

We apply grease to the inner surfaces of the clutch release fork bushings, as well as to the outer surface of the bearing guide bushing.

We replace the torn rubber boot of the clutch release fork lever with a new one.