Clutch: Service and Repair

Clutch Pressure and Driven Plate Replacement

Special Tools

* DT-6263 - Remover / Installer

* DT-6263-27 - Clutch Center Guide

* EN-652 - Flywheel Holder

For regional equivalent tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Note:

* To prevent damage to the spring fangs of pressure plate use the DT-6263 - remover / installer to remove and install the clutch pressure plate.

* Note the different lengths of the brackets for installing the DT-6263 - remover / installer to the lower engine block.

1. Remove the transmission. Refer to Transmission Replacement Transmission Replacement.




2. Remove and DISCARD the upper transmission locating pin (1) from the engine block.




3. Install the EN-652 - holder (1) to the engine block.




4. Install the DT-6263 - remover / installer (1) along with the DT-6263-1 - brace to the engine block.

5. Install the 4 bolts (arrows) to the engine block, but do not tighten yet.




6. Install the DT-6263-27 - guide (5) to the DT-6263-30 - drift (4).

7. Tighten the DT-6263 - remover / installer.

1. Align the DT-6263-30 - drift (2) along with the clutch center guide through the DT-6263 - remover / installer into the clutch driven plate and the crankshaft center (arrow).

2. Tighten the knurled wheel (1).

3. Tighten the bolt (3).

4. Tighten the 4 bolts installing the DT-6263 - remover/installer to the engine block.




8. Preload the clutch springs, using the DT-6263 - remover / installer.

1. Turn the threaded rod (1) until it rests against the spring tangs of the clutch pressure plate.

2. Measure the distance a.

Note: DO NOT turn further than necessary in order to gain free movement of the clutch disc.

3. Turn the threaded rod clockwise until the distance a is extended by approx. 8 mm (0.31 in).

4. Check for free movement of the clutch disc.





Note: Make sure if bolts was assembled with thread lock agent.

9. Remove and DISCARD the 6 clutch pressure plate bolts (1).




10. Release the DT-6263 - remover / installer (2).

1. Turn the threaded rod (1) of the DT-6263 - remover / installer counterclockwise to the stop.

2. Remove the DT-6263-30 - drift (3) along with the clutch center guide (arrow).




11. Remove the clutch pressure plate (1) and the driven plate (2).





Note: Clutch pressure plate and driven plate contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check the clutch driven plate for damage and friction rust in the hub profile and replace it if necessary. DO NOT clean the clutch pressure plate and the driven plate with a high pressure cleaner or component washing machine.

12. Inspect the clutch pressure plate and the driven plate (1) and replace it, if necessary:

* Excessive wear

* Burned friction surface

* Oil on friction surface

* Damaged spline hub

* Damaged springs

Note: The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in) (arrows).

13. Inspect the projection of the lining at the clutch lining rivets.

14. Slide the clutch pressure plate onto the transmission input shaft and check for easy movement.

Installation Procedure





1. Install the bushing (1) to the crankshaft. The bushing stays in the crankshaft. For the correct bushing refer to the electronic parts catalog.




2. Re-cut the 6 clutch pressure plate bolt threads.

Note: The clutch driven plate must be installed so that the German lettering "Getriebeseite" (means Gearbox-side) on the plate is orientated towards the transmission.

3. Install the clutch driven plate (3) and the clutch pressure plate (2).

4. Center the clutch driven plate, using the DT-6263-30 - drift (1) along with the clutch center guide.





Note: DO NOT turn further than necessary.

5. Preload the clutch springs, using the DT-6263 - remover / installer (2).

6. Turn the threaded rod (1) clockwise until the pressure plate contacts the flywheel (arrows).





Caution: Refer to Fastener Caution Fastener Caution.

Note: In the case that the clutch pressure plate bolts where assembled with thread lock agent: Service may offer bolts that are not microencapsulated. If this is the case apply thread lock agent to the bolt. If the fastener is microencapsulated, install NEW clutch pressure plate bolts. DO NOT reuse the old bolts.

7. Install the 6 NEW clutch pressure plate bolts (1). For the correct bolts refer to the electronic parts catalog.

8. Tighten the clutch pressure plate bolts to 24 Nm (18 lb ft).




9. Remove the DT-6263 - remover / installer (2) from the engine block.

1. Turn the threaded rod (1) of the DT-6263 - remover / installer counterclockwise to the stop.

2. Remove the DT-6263-30 - drift (3) along with the clutch center guide (arrow).

3. Remove the 4 bolts holding the DT-6263 - remover / installer to the engine block.




10. Remove the EN-652 - holder (1) from the engine block.




11. Install a NEW upper transmission locating pin (1) to the engine block.

12. Install the transmission. Refer to Transmission Replacement Transmission Replacement.