Warning: Clutch wear produces asbestos-containing dust that settles on the mechanism components and is extremely harmful to your health. Do not blow it off with compressed air or inhale it. Do not use gasoline or gasoline-containing solvents to clean this dust. Wash the dust into the drain pan with brake system cleaner. After wiping the clutch components with a rag, put the used rag and cleaner in a closed container.
Removal
1. Remove the gearbox from the vehicle (chapter 7, Part A).
2. Use a punch to mark the position of the pressure plate relative to the flywheel so that it can be installed correctly later.
3. Loosen the pressure plate bolts in a crisscross pattern to avoid tilting the basket.
4. Unscrew and disconnect the pressure plate and the driven clutch disc from the flywheel (see figure).
3.4. Three-dimensional image of the clutch unit and its components.
1. Clutch release shaft.
2. Lubricate the seal hole.
3. Sealing sleeve.
4. Lubricate the end of the lever.
5. Pin.
6. Thrust bearing.
7. Note: Install with the spring damper facing the gearbox.
8. Slave disk.
9. Pressure disc.
10. Lubricate both eyes.
11. Pin 9 mm.
12. Thrust bearing fork.
13. Gearbox block.
5. Carefully remove the clutch, being careful not to touch the gasket surfaces.
Examination
6. Inspect the rubbing surfaces of the driven disk, pressure plate and flywheel. There may be scratches, burnt areas, deep grooves, cracks, other types of wear and damage. If the flywheel is worn or damaged, replace it (see chapter 2C).
7. To see how worn the clutch disc is, measure the distance from the rivet heads to the surface of the gasket. When removing the disc, it is recommended to replace it. Put the clutch disc on the input shaft to make sure that it fits tightly to it, and that the splines are not warped or worn.
8. Remove and inspect the thrust bearing and its fork as described in section 4.
9. Check the flatness of the pressure plate with a straight edge. Look for signs of overheating, cracks, deep grooves and burrs. The inner ends of the diaphragm spring pins should not show signs of wear. If any faults are found, replace it with a new one (see figure).
3.9. If signs of intense wear are visible, replace the clutch.
1. Normal wear of fingers.
2. Severe wear of fingers.
3. Burnt or bent fingers.
4. Serious scratches.
5. Clutch vibration.
6. Heavy wear.
10. Make sure the pressure plate fits tightly on the flywheel pins. If there is any looseness, replace it with a new one.
Installation
11. Place the driven clutch disc on the flywheel, centering it with a special tool (see figure).
12. Holding the clutch disc in place with a centering tool, place the pressure plate on the flywheel pins, aligning with the marks made during disassembly.
13. Install the bolts and tighten them in a crisscross pattern one to two turns at a time until the specified torque is achieved.
14. Install the fork and thrust bearing (see section 4).
15. Install the gearbox (see chapter 7, part A).