- elevated (compared to usual) noise when engaging the clutch;
- jerks during clutch operation;
- incomplete engagement of the clutch (clutch slips);
- incomplete clutch disengagement (clutch «leads»).
Useful advice: If the clutch fails, we recommend replacing all its elements at the same time (driven and driven discs, clutch release bearing), since the work of replacing the clutch is very laborious, and the life of intact clutch elements has already been reduced, therefore, if they are installed again, it may be necessary to replace the clutch again after a relatively short run.
You will need: key «at 11», mounting blade, mandrel for centering the driven disk.
1. Remove the gearbox (see «Removal and installation of a manual transmission»).
2. If you install the old pressure plate, mark in any way (e.g. paint) the relative position of the disc housing and the flywheel to set the pressure plate in its original position (to maintain balance).
3, holding the flywheel with a spudger (or a large screwdriver) from turning, unscrew the six bolts securing the clutch pressure plate housing to the flywheel. Loosen the bolts evenly: each bolt has two turns of the wrench, moving from bolt to bolt in diameter.
Note: This is how the clutch cover bolts to the engine flywheel are located.
4. Remove the clutch pressure and driven discs from the flywheel while holding the driven disc.
5. Examine a conducted disk of coupling. Cracks on the details of the driven disk are not allowed.
6. Check the degree of wear of the friction linings. If the rivet heads are sunk by less than 0.3 mm, the surface of the friction linings is oily, or the rivet connections are loose, then the driven disk must be replaced.
Note: If the drive plate linings are oily, check the condition of the transmission input shaft oil seal. It may need to be replaced.
7. Check up reliability of fixing of damper springs in sockets of a nave of a conducted disk, trying to move them in sockets of a nave by a hand. If the springs move easily in their seats or are broken, replace the disc.
8. Check up beating of a conducted disk if its warping is found out at visual inspection. If the runout is greater than 0.5 mm, replace the disc.
9. 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. Replace defective units.
10. If the rivet joints of the casing and pressure plate parts are loose, replace the pressure plate assembly.
11. Visually evaluate the condition of the pressure plate diaphragm spring. Cracks in the diaphragm spring are not allowed. Places A of contact between the petals of the spring and the clutch release bearing must be in the same plane and not have obvious signs of wear (wear should not exceed 0.8 mm). Otherwise, replace the pressure plate assembly.
12. Inspect the connecting links of the casing and disc. If the links are deformed or broken, replace the pressure plate assembly.
13. By external inspection, evaluate the condition of the support rings of the pressure spring from the outer...
14.... and the inside of the spring. Rings must be free of cracks and signs of wear. Otherwise, replace the pressure plate assembly.
15. Before installing the clutch, check the ease of movement of the driven disk along the splines of the input shaft of the gearbox. If necessary, remove the causes of seizing or replace defective parts.
16. Apply high-melting grease to the splines of the driven disc hub.
17. When mounting the clutch, first install the driven disk using a mandrel...
Notes: To center the clutch, make a mandrel according to fig. 6.3.
Install the driven disk so that the inscription «FLYWHEEL SIDE» pointing towards the flywheel (the protruding part of the disc hub must be directed towards the diaphragm spring of the clutch housing).
18.... and then the casing of the pressure plate, aligning the marks applied before removing, and then screw in the bolts securing its casing to the flywheel
19. Screw the bolts with a torque of 15 Nm evenly, one turn of the wrench each, alternately moving from bolt to bolt along the diameter.
20. Remove the mandrel and install the gearbox.
21. Check clutch operation (see «Checking and adjusting the travel of the clutch release pedal»).