FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Conventional Clutch, Servicing



Conventional clutch, servicing, 02X, 6-Speed Four-Wheel Drive M/T





1 - Flywheel/dual mass flywheel
^ Ensure that dowel pins fit tightly
^ Contact surface for clutch lining must be free of grooves, oil and grease

2 - Bolt for flywheel
^ Always replace
^ Bolt length: 22.5 mm; 60 Nm plus an additional 90° 1/4 turn
^ Bolt length: 43 mm; 60 Nm plus an additional 180° 1/2 turn

3 - Clutch plate
^ Installation position: Clutch lining must make full contact with flywheel
^ Marking "Getriebeseite" (transmission side), if provided, faces pressure plate/transmission.
^ Coil springs (damper assembly) point toward pressure plate and transmission
^ Centralize

4 - Pressure plate
^ Removing and installing
^ Check ends of diaphragm spring
^ Check spring connection and rivets
^ Check wire ring

5 - Bolt -22 Nm-
^ Loosen and tighten gradually in several stages and in diagonal sequence

6 - Needle bearing





Centralizing clutch plate and removing and installing pressure plate
- Loosen and tighten bolts gradually in several stages and in diagonal sequence.
- To remove, reverse position of counter-hold tool 3067 or counter-hold tool 10 - 201.

Installation position of clutch plate: coil springs (damper assembly) or marking "Getriebeseite" point toward pressure plate and transmission.
- Before tightening securing bolts, clutch lining and contact surface of pressure plate must make full contact with flywheel.





Checking ends of diaphragm spring
^ Wear up to half the thickness of the diaphragm spring is permitted.

Note:
^ When performing repairs, always match the correct clutch pressure plate and clutch plate by checking engine code.





Checking spring connection and rivet
- Check spring connections - arrowsA - for damage and make sure riveted fastenings arrowsB are seated tightly.

Note:
^ replace pressure plate if spring connections are broken or badly bent, or if riveted fastenings are loose.





Checking wire ring
- Check that wire ring in pressure plate - arrow - is not damaged. Replace pressure plate if wire ring is broken.