Replacing the clutch disc or cover assembly

CLUTCH DISC AND COVER ASSEMBLY

SPECIAL TOOLS

[1]. Universal centring tool (ref. 589 47 31 00) (Fig.1)

Fig. 1

REMOVAL

• Remove the gearbox.
• Lock the flywheel to prevent it from rotating.
• Gradually loosen the cover bolts in successive stages, then remove the cover assembly and collect the clutch disc.

If the cover assembly is reused, mark its position relative to the flywheel.

INSTALLATION

• Visually check:

• that the flywheel friction surface is free of impacts and scoring,
• the flywheel wear,
• the condition of the starter ring gear,
• the condition of the clutch cover assembly.

• If there is oil in the clutch housing, replace the crankshaft oil seal (after removing the flywheel).
• Clean the input shaft with a hand wire brush to remove all traces of oxidation.
• Observe the fitting direction (marked on the cover assembly, gearbox side).
• Fit the cover assembly and centre the disc using the universal centring tool [1] (Fig.1).
• Tighten the cover assembly to the specified torque, in successive stages.

Do not reuse a clutch disc whose hub shows signs of oxidation.

• Refit the gearbox.

Clutch

1. 1
   Clutch disc
2. 2
   Clutch cover assembly
3. 3
   Bolts:

• M6 bolts:
• 1st stage: 0.3 daN.m
• 2nd stage: 0.9 daN.m
• M8 bolts:
• 1st stage: 0.4 daN.m
• 2nd stage: 2.2 daN.m.

1. 1
   Clutch release bearing/slave cylinder
2. 2
   Bolt: 1.2 daN.m
3. 3
   Bushing
4. 4
   Bleed screw
5. 5
   Pipe
6. 6
   Master cylinder
7. 7
   Reservoir
8. 8
   Pedal bracket
9. 9
   Clutch pedal
10. 10
    Rubber pad
11. 11
    Strut bearing
12. 12
    Neutral-gear detent spring rod
13. 13
    Spring
14. 14
    Neutral-gear detent spring seat
15. 15
    Pushrod pin
16. 16
    Clutch pedal pin on pedal bracket
17. 17
    Master cylinder pin on clutch pedal.