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
Note:
To prevent damage to the spring tangs of the thrust plate use DT-6263 - remover and installerto remove and install the thrust plate.
Note the different lengths of the brackets for attaching DT-6263 - remover and installerto lower engine block. Thrust plate and clutch disc for vehicles with self-adjusting clutch (SAC) are only available in Aftersales as a set.
1. Remove the transmission. Refer to Transmission Replacement Transmission Replacement.
Note:
DT-6263 - remover and installermay 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 centring drift (5).
Caution:
Refer to Fastener Caution Fastener Caution.
4. Fasten DT-6263 - remover and installer.
1. Align DT-6263 - remover and installerin center.
2. Insert centring drift with DT-6263-30 - remover and installer(2) through DT-6263 - remover and installerinto clutch plate and crankshaft (center).
3. Tighten fastener (1)
4. Tighten fastener (3)
5. Tighten 4x fastener DT-6263 - remover and installeron 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 installerclockwise to the stop.
Note:
Illustration 2156559 gives a better view of the clutch without DT-6263 - remover and installerand centring 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) anticlockwise to the stop.
2. Pull out centring 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.
1. Attach clutch disc and thrust plate to flywheel.
Center thrust plate and clutch plate with centring 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) anticlockwise to the stop.
2. Detach centring drift and DT-6263-30 - remover and installer(2).
3. Remove 4x fastener DT-6263 - remover and installeron engine block.
4. Install the transmission. Refer to Transmission Replacement Transmission Replacement.