We replace the clutch when the driven and driving discs are worn out
Mount the vehicle on a pit or lift
Remove the gearbox.
Remove the ten mounting bolts and remove the clutch housing.
Fix the flywheel with a screwdriver 1, unscrew evenly diagonally six bolts 2 fastening the pressure plate to the flywheel and remove the pressure plate 3 and the driven plate, while holding the driven plate.
Remove the four bolts securing the clutch booster to the engine block, lift the rear of the engine and remove the clutch booster 1
Inspection and Troubleshooting of Clutch Parts
1. Clean the pressure and driven discs, as well as the working surface of the flywheel, from dust and dirt.
2. Inspect the driven disk. Cracks on the parts of the driven disk are not allowed.
Check wear of friction linings 1.
If the rivet heads 2 are sunk less than 0.2 mm, the surface of the friction linings is oily or the rivet connections are loose, then the driven disk (or friction linings) must be replaced.
Check the reliability of fixation of damper springs 3 in the sockets of the hub of the driven disk.
If the springs are broken, the disc needs to be replaced.
On the friction washer 4, located under the pressure spring 5 of the torsional vibration damper, signs of wear, overheating or mechanical damage are not allowed.
Check the runout of the driven disk if warping is found during visual inspection. If the runout exceeds 0.7 mm, replace the disc.
3. Inspect the friction surfaces of the flywheel and pressure plate, paying attention to the absence of deep scratches, scuffs, nicks, obvious signs of wear and overheating.
Loosening the rivet connections of the pressure plate parts is not allowed.
In the presence of these defects, it is recommended to replace the nodes.
4. By external examination, evaluate the condition of the support rings 1 and the diaphragm spring 2 of the pressure plate. Support rings must be free of cracks and signs of wear.
Cracks in the diaphragm spring are not allowed.
The points of contact (shown by the arrow) of the spring petals with the clutch release bearing must be in the same plane and not have obvious signs of wear.
5. Checking the location of the ends of the petals of the spring and their adjustment is carried out on a special device or on a removed flywheel.
To check, it is necessary to mount the pressure plate 2 on the removed flywheel 3, after placing three washers 1 8 mm thick under the working surface of the pressure plate, placing them at an angle of approximately 120 ° to each other.
Measure the distance from the end of the flywheel to the end of the petal 4. This dimension should be (42.5±2) mm.
Similarly, check this size on other petals.
Protrusion (drowning) of the spring petals relative to each other by no more than 0.25 mm is allowed.
Otherwise, the ends of the petals that do not lie in a plane must be bent.
After checking the position of the petals, the amount of movement of the working part of the pressure disk is checked.
To check, it is necessary to apply force to all petals 4 so that they move from their original position to a depth of 8.5 mm, while the gap between pressure plate 2 and washers 1 must be at least 1.3 mm.
Remove the washers, to do this, increase the force on the ends of the petals so that they move about 10 mm.
Installation
1. Lubricate the input shaft front bearing located in the flywheel with Litol-24 grease.
- 2. Check the ease of movement in the axial direction of the driven clutch disc along the splines of the input shaft. If movement is difficult, remove burrs from splines.
- 3. Insert a mandrel made according to the specified dimensions into the input shaft front bearing located in the flywheel.
4. Install the clutch disc on the mandrel.
In this case, orient the driven plate so that the protruding part of the driven plate hub faces the pressure plate.
- 5. Install the pressure plate and tighten the six bolts of its fastening without tightening.
- 6. In the absence of a centering mandrel, a spare input shaft can be used. In this case, put pressure and driven disks on the input shaft in accordance with their orientation.
Insert the input shaft into the front bearing located in the flywheel and tighten the six bolts securing the pressure plate, without tightening.
- 7. Final tighten the six pressure plate mounting bolts evenly diagonally to 20–25 Nm (2–2.5 kgfm).
- 8. Check the tightness of the ball stud nut on the clutch housing.
Lubricate the ball surface of the finger with a thin layer of Litol-24 grease.
- 9. Install the clutch booster, if it was removed, and tighten the four bolts securing the booster to the cylinder block to a torque of 29–36 N m (2.9–3.6 kgf m).
- 10. Install the crankcase on the cylinder block and tighten the bolts of its fastening.
