Clutch: Service and Repair
Clutch Pressure and Driven Plate Replacement
Special Tools
DT-6263 - Remover / Installer or equivalent.
For equivalent regional tools, refer to Special Tools M20/M32 - Manual Transmission.
Removal Procedure
1. Remove transmission. Refer to Transmission Replacement Removal and Replacement.
Note: Discard the bolts.
2. Remove 6 clutch pressure plate bolts (1).
3. Remove clutch pressure plate (2) and driven plate (1).
Note: Clutch pressure plate and driven plates contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check clutch driven plate for damage and friction rust in the hub profile and replace if necessary. Do not clean clutch pressure plate and driven plate with a high pressure cleaner or component washing machine.
4. Inspect clutch pressure plate and driven plate (1) and replace if necessary.
Inspect for:
* Excessive wear
* Burned friction surface
* Oil on friction surface
* Damaged spline hub
* Damaged springs
5. Inspect projection of lining at the clutch lining rivets.
Note: The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in) (arrows).
6. Slide clutch driven plate onto the transmission input shaft and check for easy movement.
Installation Procedure
1. Clean 6 threads in flywheel for fastening clutch pressure plate.
Note: The clutch driven plate must be installed so that the lettering on the hub faces the transmission.
2. Install driven plate (1) and clutch pressure plate (2).
Note:
* To prevent damage to the spring fangs of pressure plate use DT-6263 - remover / installer or equivalent to remove and install clutch pressure plate.
* Note the different lengths of the brackets for attaching DT-6263 - remover / installer or equivalent to lower engine block.
Note: DT-6263 - remover / installer or equivalent may only be attached to the engine block and not to the oil pan.
3. Attach DT-6263 - remover / installer (1) or equivalent to engine block.
Note: Do not tighten the bolts yet.
4. Install 4 bolts (arrows) to engine block.
5. Attach DT-6263-27 - center guide (5) or a fitting equivalent to DT-6263-30 - centering drift (4) or equivalent.
6. Fasten DT-6263 - remover / installer.
* Align DT-6263 - remover / installer or equivalent to center.
* Insert DT-6263-30 - centering drift or equivalent (2) in conjunction with clutch center guide through DT-6263 - remover / installer or equivalent into clutch pressure plate and crankshaft center (arrow).
* Tighten knurled wheel (1).
* Tighten bolt (3).
* Tighten 4 bolts of DT-6263 - remover / installer or equivalent to the engine block.
7. Preload clutch springs using DT-6263 - remover / installer or equivalent.
* Move DT-6263 - remover / installer (1) or equivalent that it rests against the spring tangs of clutch pressure plate.
* Turn DT-6263 - remover / installer or equivalent clockwise to the stop.
Caution: Refer to Fastener Caution Fastener Caution.
8. Install 6 NEW clutch pressure plate bolts (1) and tighten crosswise to 28Nm (21 lb ft).
9. Remove DT-6263 - remover / installer (1) or equivalent from engine block.
* Turn DT-6263 - remover / installer (3) or equivalent counterclockwise to the stop.
* Remove DT-6263-30 - centering drift (2) or equivalent in conjunction with clutch center guide (arrow).
* Remove 4 bolts of DT-6263 - remover / installer or equivalent from the engine block.
10. Install transmission. Refer to Transmission Replacement Removal and Replacement.