Clutch: Service and Repair
Clutch Assembly Replacement
Special Tools
DT-6263 - Remover and Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment).
Removal Procedure
1. Remove the transmission.
Note:
* To prevent damage to the spring tangs of the thrust plate use DT-6263 - remover and installer to remove and install the thrust plate.
* Note the different lengths of the brackets for attaching DT-6263 - remover and installer to lower engine block. Thrust plate and clutch disc for vehicles with self-adjusting clutch (SAC) are only available in After sales as a set.
* DT-6263 - remover and installer may only be attached to the engine block and not to the oil pan, do not tighten bolts yet.
2. Attach DT-6263 - remover and installer (1) to engine block.
3. Attach DT-6263-30 - remover and installer (4) to centering drift (5).
Caution: Refer to Fastener Caution (Fastener Caution).
4. Fasten DT-6263 - remover and installer.
1. Align DT-6263 - remover and installer in center.
2. Insert centering drift with DT-6263-30 - remover and installer (2) through DT-6263 - remover and installer into clutch plate and crankshaft (center).
3. Tighten fastener (1)
4. Tighten fastener (3)
5. Tighten 4x fastener DT-6263 - remover and installer on engine block.
5. Relieve stress on clutch disc.
1. Move DT-6263 - remover and installer (1) so that it rests against spring tangs of the thrust plate.
2. Turn DT-6263 - remover and installer clockwise to the stop.
Note: Illustration 2156559 gives a better view of the clutch without DT-6263 - remover and installer and centering drift.
6. Remove thrust plate from flywheel. Remove 6 fasteners.
7. Detach thrust plate and clutch plate.
1. Turn DT-6263 - remover and installer (1) counterclockwise to the stop.
2. Pull out centering drift with DT-6263-30 - remover and installer (2).
Note: Clutch plates contaminated by foreign bodies (oil, cleaning agent etc.) must be replaced as a matter of principle. Check clutch disc for damage and friction rust in the hub profile and replace if necessary. Do not clean thrust plate and clutch disc with a high pressure cleaner or component washing machine.
8. Check clutch plate for wear: Check the projection of the lining at the clutch lining rivets. The clutch plate must be replaced if the lining projection is less than 0.5 mm. Also, press the clutch plate onto the transmission input shaft and check for ease of movement.
Installation Procedure
Note: Lettering "transmission side" faces the transmission.
* Do not tighten bolts yet.
* For a clearer representation, clutch shown without DT-6263 - remover and installer.
1. Attach clutch disc and thrust plate to flywheel.
Center thrust plate and clutch plate with centering drift and DT-6263-30 - remover and installer (1).
Note: Tighten fastener crosswise.
2. Attach thrust plate to flywheel and turn DT-6263 - remover and installer (1) clockwise to the stop.
* Tighten the trust plate - fastener M7 to 15 Nm (11 lb ft).
* Tighten the trust plate - fastener M8 to 22 Nm (16 lb ft).
3. Detach DT-6263 - remover and installer (1) from engine block.
1. Turn DT-6263 - remover and installer (3) counterclockwise to the stop.
2. Detach centering drift and DT-6263-30 - remover and installer (2).
3. Remove 4x fastener DT-6263 - remover and installer on engine block.
4. Install the transmission.