2. Clutch wear is highly dependent on driving style. Slipping while driving will accelerate the wear of the friction disc. It is recommended to change the friction disc every 64,000 km.
3. To access the clutch, remove the gearbox (Chapter 7).
4. After removing the gearbox, inspect the clutch from the outside and check the condition of the diaphragm spring pins on the clutch housing. If any damage is found, (deformation or bending of fingers) replace the clutch housing assembly with the spring.
5. Gradually, in a diagonal sequence, loosen the bolts until the spring tension is released (photo). Do not damage the pressure plate. Secure the flywheel from turning by inserting a screwdriver into the starter opening.
7.5 Clutch bolt release procedure
6. Unscrew the bolts, remove the clutch housing, pressure plate and friction disc (photo).
7.6 Removing the clutch
7. Clean the pressure plate, flywheel and bearing holder from grease and dirt.
8. Check the condition of the pressure plate surface for nicks, dents and scratches. Check the condition of the diaphragm spring petals and the lining. Check the deformation of the petals using a feeler gauge (unevenness of petal height, photo), make sure that this value does not exceed the limit specified in the Technical Data. If any defects are found, replace the clutch assembly.
7.8 Checking the deformation of the diaphragm spring petals
9. Check the wear of the friction disc. Replace the disc if the distance from the friction lining surface to the rivet heads is less than 0.8 mm, or if there is any damage or oil stains on the friction material.
10. Check the condition of the flywheel surface. If there are shallow damages, then grind the flywheel. If there is significant damage, (breakages on the gear ring, traces of burning on the friction surface) replace the flywheel (Chapter 2).
11. If traces of oil are found on the clutch parts, determine the cause and eliminate it. If oil is found on the clutch housing side, replace the gearbox primary shaft seal.
12. It is recommended to replace the release bearing. Check the bearing guide bush for wear, replace if necessary (see below).
13. Before assembly, apply a thin layer of molybdenum grease to the splines of the input shaft.
14. Before installing the clutch, center the friction disc relative to the flywheel using a mandrel or suitable tool (photo).
7.14 Before tightening the bolts, center the friction disc relative to the flywheel
15. Install the clutch basket onto the guide pins. Tighten the bolts in a diagonal sequence in several stages until the specified torque is reached (photo).
16. Install the gearbox.