Withdrawal
1. Drain the clutch fluid and oil from the gearbox housing.
2. Remove a transmission in gathering.
3. Install the special tool (09411-11000) into the driven disk to prevent it from falling out.
4. Loosen the bolts securing the clutch cover to the flywheel in the sequence "by star".
Loosen each bolt one or two turns each time "to avoid warping of the clutch housing flange.
Note. Do not clean the clutch disc and thrust bearing with detergents.
5. Remove the spring collar and release bearing.
6. Install special tool (09414-24000) into the spring pin and thread the round nut onto the end of the tool.
Warning. Do not clean the clutch disc and thrust bearing with detergents.
7. Holding the special tool shaft (09414-24000), turn the bushing with a wrench to unscrew the spring pin.
8. Remove the clutch fork shaft, retaining ring, return spring and the fork itself.
Checking the clutch assembly
1. Check the ends of the diaphragm spring for wear and equal height.
Replace it if the wear is significant or if the height difference exceeds 0.5 mm.
2. Check for wear, cracks and discolouration of the pressure plate surface.
3. Check for loose rivets, replace clutch cover assembly if necessary.
Clutch disc
1. Check the surface for protruding rivets, uneven contact, warpage, oil or dirt, and replace the driven disk if necessary.
2. Measure the rivet recess and replace the driven disk if it is less than 0.3mm.
3. Check up damage of a spring, at its malfunction replace a conducted disk.
4. Clean the input shaft splines and install the clutch disc. If the disc does not move smoothly or has play, replace the driven disc and/or input shaft.
Clutch release bearing
Warning. The release bearing contains factory grease. Do not use detergent or oil to clean it.
1. Check for binding, damage, and noisy operation of the bearing, as well as wear on the contact points of the diaphragm spring.
2. Replace the bearing if the clutch fork contact points show excessive wear.
Clutch fork
1. Replace the clutch fork if its contact points with the release bearing show excessive wear.
Installation
1. Apply MOLYWHITE TA No. 2 multipurpose grease to the fork shaft. Fill the grooves on the clutch cover with it according to the picture.
2. Align the holes on the fork with the fork shaft and install the new spring pins in the holes.
3. Pack MOLYWHITE TA No. 2 grease into the release bearing groove.
4. Apply the same lubricant to the contact surface of the clutch fork with the release bearing.
5. Thoroughly clean the surfaces of the flywheel and pressure plate with fine sandpaper and make sure that oil and grease are completely removed.
6. Apply a small amount of MOLYWHITE TA No. 2 grease to the splines of the driven disc and input shaft.
7. Using a special tool (09411-11000), install the clutch disc onto the flywheel, making sure the maker's mark is on the pressure plate side.
8. Install the clutch cover assembly to the flywheel and fit the six clutch cover to flywheel bolts.
9. Tighten the bolts sequentially diagonally to a torque of 15-22 Nm.
Turn each bolt one or two turns each time to avoid warping of the casing flange.
10. Install the gearbox.
11. Adjust the clutch pedal free play.