Removal
Remove the gearbox, see p. 10.1.
To prevent the flywheel from turning while unscrewing the bolts, the flywheel ring gear must be locked using a screwdriver and a mandrel.
Loosen the clutch pressure plate mounting bolts crosswise by 1-1.5 turns, as a result the pressure plate should become free.
Caution: If you completely loosen the bolts immediately, you may damage the diaphragm spring.
Finally, completely unscrew the bolts.
Remove the clutch pressure and driven discs.
Caution! Try not to drop the pressure and driven clutch discs during their dismantling, otherwise various problems may arise during installation.
Wipe the flywheel with a rag soaked in gasoline.
Examination
If you are using a used pressure plate or slave plate, they must be inspected before installation.
Clutch discs coated with grease or with mechanical defects must not be installed.
Using a caliper, measure the thickness of the friction linings on the clutch discs. The thickness of the linings to the top of the rivet heads should be at least 0.3 mm, otherwise replace the driven disc. If the friction linings are cracked, the driven discs must also be replaced.
Check the pressure plate. Traces of wear on the ends of the membrane spring up to 0.3 mm deep are not significant.
Check the spring connections between the clutch pressure plate and cover for cracks and for a secure fit. Replace pressure plates with damaged or loose rivets.
Check the bearing surface of the pressure plate for cracks, burnt areas and wear. Pressure plates with an inward deflection of up to 0.3 mm can be installed. Check using a template and a ruler. Small cracks and grooves on the flywheel and pressure plate are removed with fine sandpaper.
Check the window springs, torsion springs, mounting rivets and hubs for wear and tear.
Installation
Check the smooth running of the clutch release bearing. The bearing should operate silently.
Before installing a new clutch, it is necessary to completely remove the anti-corrosion grease from the pressure plate.
Thoroughly clean the internal splines of the driven disc and the splines of the transmission input shaft, as well as the guide sleeve of the clutch release bearing.
Lubricate the splines of the drive shaft and the guide bushing with a thin layer of special grease (Microlube GL-261). In this case, it is necessary to lubricate the entire surface of the splines.
Caution! Do not apply too much grease, as during vehicle operation the excess grease will be thrown onto the friction surfaces, resulting in reduced clutch efficiency. Using other types of grease may cause shifting problems.
Position the driven clutch disc in the center of the pressure plate by eye. It is better to center the disc using a suitable mandrel, such as HAZET 2174, or using the old gearbox drive shaft. Ford workshops have a special tool 16-067 for this purpose. If the driven clutch disc is not centered, it will not be possible to install the gearbox drive shaft at a later stage.
Install the pressure plate with the driven disk centered in the corresponding fitting pins on the flywheel.
Install the mounting bolts for the clutch pressure plate, tighten them by hand first, then tighten the bolts crosswise in stages by 1-1.5 turns, do this until the pressure plate is firmly seated on the flywheel.
Caution! Make sure that the pressure plate is pulled into the flywheel evenly and without burrs when tightening the bolts. The tightening torque of the pressure plate mounting bolts is 30 Nm.
Remove the centering mandrel.
Install the gearbox, see p. 10.1.
Check the clutch adjustment, see p. 9.3.