Clutch: Service and Repair

Clutch Assembly Replacement

Special Tools

DT-6263 Remover and Installer

For equivalent regional tools, refer to Special Tools.

Removal

1. Remove the transmission. Refer to Transmission Replacement (FWD, LBS/A20DTH) Transmission Replacement (All Wheel Drive - LBY/A20DTR) Transmission Replacement (Front Wheel Drive - LBY/A20DTR) Transmission Replacement (AWD, LHU/A20NFT) Transmission Replacement (FWD, LHU/A20NFT).

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 Aftersales as a set.

2. Note
The remover and installer DT-6263 must only be fitted to the engine block, not to the oil sump. Do not tighten bolts yet.

Attach DT-6263 remover and installer (1) to engine block.





3. Attach DT-6263-30 remover and installer (4) to centering drift (5).





4. Refer to Fastener Caution.

Attach remover and installer DT-6263.

- Align DT-6263 remover and installer in center.
- Insert centering drift with DT-6263-30 remover and installer (2) through DT6263 remover and installer into clutch plate and crankshaft (center).
- Tighten fastener (1)
- Tighten fastener (3)
- Tighten 4x fastener DT-6263 remover and installer on engine block.

5. Relieve stress on clutch disc.





- Move DT-6263 remover and installer (1) so that it rests against spring tangs of the thrust plate.
- Turn DT-6263 remover and installer clockwise to the stop.

6. Note
The illustration gives a better view of the clutch without DT-6263 remover and installer and centering drift.

Remove thrust plate from flywheel. Remove 6 fasteners.





7. Detach thrust plate and clutch plate.





- Turn DT-6263 remover and installer (1) anticlockwise to the stop.
- Pull out centering drift with remover and installer DT-6263-30 (2).

8. 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.

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.





Assemble

1. Note
Lettering "transmission side" faces the transmission.
- Do not tighten bolts yet.
- For a clearer representation, the illustration shows clutch without DT-6263 remover and installer.

Attach clutch disc and thrust plate to flywheel.

Center thrust plate and clutch plate with centering drift and remover and installer DT-6263-30 (1).





2. Note
Tighten fastener crosswise.

Attach thrust plate to flywheel and turn DT-6263 remover and installer (1) clockwise to the stop.





- Tighten the thrust plate - fastener M7 to 15 Nm (11 lb ft).
- Tighten the thrust plate - fastener M8 to 22 Nm (16 lb ft).

3. Detach DT-6263 remover and installer (1) from engine block.





- Turn DT-6263 remover and installer (3) anticlockwise to the stop.
- Detach centering drift and remover and installer DT-6263-30 (2).
- Remove 4x fastener DT-6263 remover and installer on engine block.
4. Install the transmission. Refer to Transmission Replacement (FWD, LBS/A20DTH) Transmission Replacement (All Wheel Drive - LBY/A20DTR) Transmission Replacement (Front Wheel Drive - LBY/A20DTR) Transmission Replacement (AWD, LHU/A20NFT) Transmission Replacement (FWD, LHU/A20NFT).