Next, remove the six bolts securing the shroud. Loosen the bolts gradually and sequentially around the circumference, no more than two turns of the wrench at a time, so as not to bend the pressure plate housing supports.
Fig. 4. Clutch disc
After removing the bolts, the pressure and driven discs (Fig. 4) can be freely removed downwards.
Install discs on the car in reverse order.
Before installing, do the following:
- 1. Wipe all friction surfaces of discs and flywheel with a clean cloth dampened with gasoline.
- 2. Blow out the parts of the clutch discs with air and inspect them for possible defects.
- 3. Add grease to the gearbox input shaft bearing mounted on the crankshaft.
- 4. Install the driven and pressure plates in the clutch housing and center the driven disk relative to the flywheel through the rear hole of the clutch housing using drift 55–1187, which is included in the crankshaft bearing.
Instead of a mandrel, you can use the input shaft of the gearbox.
The short end of the driven disc hub must face the flywheel.
Fig. 5. Setting the chaining by labels: 1 - labels
- 5. Align the “O” marks (see Fig. 5) on the flywheel and pressure plate casing and tighten the six casing mounting bolts.
Tighten the bolts evenly and consistently around the circumference.
Disassembling the pressure plate
Fig. 6. Removing the clutch cover
The parts of the pressure plate are under the action of six springs. Therefore, before unscrewing the bolts for fastening the retractable lever supports, they should be unloaded by compressing the disc with a press, as shown in Fig. 6.
Disassemble the pressure plate in the following order:
- 1. Make marks on the casing and disc of their relative position so as not to disturb the balance during assembly.
Also make marks on the levers and pressure plate.
- 2. Unscrew the three bolts securing the casing to the support of the release levers.
- 3. Slowly release the casing from under the press, remove the casing, springs and spring washers.
- 4. Unpin and remove the fingers of the retractable levers, remove the lever supports (forks) and remove the rollers from the levers.
Pressure plate assembly
Assemble the pressure plate as follows:
1. Lay 19 rollers in the holes of the retractable levers. For ease of assembly, so that the rollers do not fall out, lubricate them with Litol-24 grease.
Do not use grease for this purpose.
In the absence of lubrication, the rollers can be assembled using a cylindrical mandrel with a diameter of 8 mm and a length of 9 mm, around which dry rollers are placed in the holes.
After installing the rollers, lubricate them with 2-3 drops of gear oil.
Fig. 7. Pressure plate with clutch release levers installed
- 2. Insert the assembled release levers into the grooves of the pressure plate in accordance with the marking made during disassembly, insert the fingers of the levers (the mandrels will come out) and cotter them (Fig. 7).
- 3. Install the support forks on the levers so that the finger is located towards the pressure plate, and the roller is towards the casing.
Splint the fingers of the forks.
4. Assemble the disc with the casing and springs under pressure to compress the springs and screw the bolts into the support forks.
Place the driven disc (or a template that replaces it, 9.5 mm thick) under the press.
On the driven disk, put the pressure, assembled with levers; install heat-insulating washers and springs on the protrusions for the pressure springs.
5. Install the clutch cover on the pressure plate so that the marks made during disassembly match.
Make sure that each spring hits the corresponding tab in the casing.
Press the cover against the table until it stops, as shown in fig. 5. There should be no distortion of the casing.
Tighten the three support fork bolts.
6. Adjust the position of the heads of the adjusting bolts of the release levers.
Replacing the friction linings of the driven disc
Replace the friction linings of the driven disk if cracks have formed in the linings or holes for rivets have developed, and also if the linings are worn so that less than 0.5 mm remains from the friction surface to the heads of the rivets.
As a general rule, if one pad is replaced, the other should also be replaced.
To replace the pads, carefully drill out the rivets that secure them (rivet shaft diameter 4 mm) and remove the remnants of the rivets so as not to damage the disc spring plates.
After replacing the pads, check the runout of the friction surfaces of the new pads relative to the spline.
The runout measured at a radius of 125 mm should not exceed 0.7 mm.
If it exceeds the specified value, then the slave disk must be edited.