Clutch Disc: Service and Repair

5 Speed Manual 02J

Clutch, Servicing
Transmission Removed and equipment required
Special Tools





- 3190 A Mandrel





- 3067 Counter-hold tool

Note:
- Replace clutch discs and pressure plates that have damaged or loose rivets
- Select correct clutch plate and pressure plate according to parts list and engine code.





1. Flywheel
- Ensure centering pins are a tight fit
- Contact surface for clutch lining must be free of grooves, oil and grease
- Removing and installing. Refer to Flywheel, M/T.
2. Clutch plate
- Diameter. Refer to Specifications
- Installation position on two-part flywheel: shorter hub end (arrow) faces pressure plate
- Installation position with single piece flywheel: spring cage faces pressure plate
- Centering refer to Fig. 1
- Lightly grease splines

Note: Clean input shaft splines and on used clutch plates, the hub splines. Remove corrosion and apply only a very thin coating of grease Part No: G 000100 to the input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely. Excess grease must be removed.

3. Pressure plate
- Removing and installing refer to Fig. 1
- Check ends of diaphragm spring refer to Fig. 2

Note: Pressure orates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

4. Bolt
- Allocate using parts catalog
- On two-part flywheel: 13 Nm
- On single piece flywheel: 20 Nm
- Loosen and tighten gradually and diagonally





Fig. 1 Centering clutch disc; removing and installing pressure plate
- Loosen and tighten bolts gradually and diagonally.
- Reverse position of retainer 3067 when removing.

Note: Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centering holes in the pressure plate housing and the centering pins in the flywheel.





Fig. 2 Checking ends of diaphragm spring
- Wear up to half thickness of the diaphragm spring is permitted.