02J, 5 SPD. M/T

Clutch, servicing, 02J, 5 Spd. M/T

(Transmission removed)

Special tools and equipment

3190 A Mandrel:

3067 Counter-hold tool:

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

1. Flywheel
^ Make sure centering pins are a tight fit
^ Contact surface for clutch lining must be free of grooves, oil and grease





2. Clutch plate
^ Diameter
^ Installation position on two-part flywheel: Shorter hub end (arrow) points toward pressure plate
^ Installation position with single piece flywheel: spring cage faces pressure plate
^ Centering
^ 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 000 100 to the input shaft splines. Then move clutch plate to and from on input shaft until hub moves freely on shaft. Excess grease must be removed.





3. Pressure plate
^ Removing and installing go to fig. 1
^ Check ends of diaphragm spring go to fig. 2

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

4. Bolt
^ Determine correct application 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 plate and 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 centralizing holes in the pressure plate housing and the centralizing pins in the flywheel.





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