2. Clutch wear is highly dependent on driving style. Slippage 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, you must remove the gearbox (Ch. 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 the fingers) replace clutch cover assembly with spring.
5. Gradually, in a diagonal sequence, loosen the bolts until the spring tension is relieved (photo). Do not damage the pressure plate. Secure the flywheel from turning by inserting a screwdriver into the starter opening.
7.5 How to loosen the clutch bolts
6. Remove the bolts, remove the clutch cover, pressure plate and friction plate (photo).
7.6 Removing the clutch
7. Clean the pressure plate, flywheel and bearing holder from grease and dirt.
8. Check up a condition of a surface of a pressure disk presence on it of scuffs, dents and scratches. Check the condition of the diaphragm spring petals and the palm Check the deformation of the petals with a feeler gauge (uneven petals in height, photo), make sure that this value does not exceed the limit given 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 friction disc wear. 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 up a condition of a surface of a flywheel. If it has shallow damage, grind the flywheel. For significant damage (breakage on the ring gear, traces of burnout on the friction surface) flywheel replace (Ch. 2).
11. If traces of oil are found on the clutch parts, then establish the cause and eliminate it. If oil is found on the side of the clutch housing, then replace the gearbox input shaft oil seal.
12. It is recommended to replace the release bearing. Check bearing guide bush for wear, replace if necessary (see below).
13. Before assembly, apply a thin layer of molybdenum grease to the input shaft splines.
14. Before installing the clutch, center the friction disc on the flywheel using a mandrel or a suitable tool (photo).
7.14 Align the friction disc with the flywheel before tightening the bolts
15. Install the clutch basket on the guide pins. Screw in the bolts and tighten in a diagonal sequence in several stages until the specified torque is reached (photo).
16. Install the gearbox.